- Uninterruptible Power Supply:
- UPSB505 (S/N: YTM1-UP)
Introduction
The Special Instruction contains information for pre-commissioning IGBT on certain UPSB505 Uninterruptible Power Supplies.
Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury.
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 recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.
The user 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.
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Power source must be disconnected before working on equipment. Failure to disconnect power source could result in injury or death. |
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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures. |
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Personal injury or death can result from high voltage. Moisture can create paths of electrical conductivity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls "DO NOT OPERATE". |
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Procedure for Pre-Commissioning IGBT
Perform the following procedure for pre-commissioning the IGBT:
Visual Check
- Ensure that the ribbon cable must be connected correctly on to the driver board in all IGBT modules. Refer to Illustration 1.
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| Illustration 1 | g03297317 |
(1) Ribbon cable (2) Interlocking location of driver board (3) Connector pins | |
- Check that all driver boards are interlocked correctly. Refer to Illustration 2.
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| Illustration 2 | g03297318 |
(3) Connector pins | |
- Ensure that all pins from connectors must be aligned on the driver board. Refer to Illustration 1 and Illustration 2.
- Make sure that the chokes are correctly cabled at the rear of unit.
- Make sure that all communication cables and the battery circuit breaker monitoring cables are separated properly from the power cables.
- Check the color of shockwatch in the product: If the color is red, replace all IGBTs before the start-up. If the color is white, there has been no excessive shock to the product and there is no need to replace the IGBT's. Refer to Illustration 4 and Illustration 5.
A shockwatch is installed in the product to check if the UPS suffered a significant mechanical constraint after removing packaging. If the color is red, the probability to have an issue during startup is more.
Note: shockwatch has been installed in UPS manufactured after 01April 2012, in all manufacturing lines.
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| Illustration 3 | g03297377 |
(4) Location of shockwatch label in UPS | |
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| Illustration 4 | g03297378 |
Shockwatch label (White) | |
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| Illustration 5 | g03297379 |
Shockwatch label (Red) | |
Application of Previous Service Publications
- Refer to SIS Web for Special Instructions related to UPS.
Firmware Update
- Update the UPS or SSC with the latest firmware version.
Note: The new software is available in the form of a flash file through Caterpillar Service Information System (SIS). Go to SIS Web to make sure that the new flash file part number is still the latest flash file part number. A newer flash file part number may be available. SIS only displays the latest available flash file.
Manual Mode Start-Up
- Start the UPS with MTEST boards in manual mode.
Note: Manual mode is mandatory for the start-up of all UPS with MTEST boards. DO NOT skip this sequence.
- Use the manual mode after repairing an IGBT power section.
Standard Mode Start-Up
- Restart the UPS in standard mode after starting the UPS in manual mode.
- Perform several transfers from the inverter to AC bypass.
- Perform several transfers from AC Normal to battery by switching "Q1", and also upstream "Q1".
Note: AC Normal power is in OFF position by default on customer panel.
- Perform several sequences from complete power OFF to power ON.
- Close and open "Q5N" several times with the inverter in coupled and not coupled mode.