PRODUCT IMPROVEMENT PROGRAM FOR REPOSITIONING THE PHASE A, B, AND C SYSTEM CABINET INPUT CABLES ON CERTAIN UPS250IE, UPS300E, UPS500, UPS600, UPS750, AND UPS900 UNINTERRUPTED POWER SUPPLY (UPS) SYSTEMS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPOSITIONING THE PHASE A, B, AND C SYSTEM CABINET INPUT CABLES ON CERTAIN UPS250IE, UPS300E, UPS500, UPS600, UPS750, AND UPS900 UNINTERRUPTED POWER SUPPLY (UPS) SYSTEMS

Usage:

SEBE8690

March 12, 2004
U-68
A-47
D-51
O-55

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPOSITIONING THE PHASE A, B, AND C SYSTEM CABINET INPUT CABLES ON CERTAIN UPS250IE, UPS300E, UPS500, UPS600, UPS750, AND UPS900 UNINTERRUPTED POWER SUPPLY (UPS) SYSTEMS
4459		PI10294

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10294" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI10294" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

PROBLEM

The Phase A, B, C System Cabinet Input Cables may have been incorrectly routed. This incorrect routing may cause wear and a consequent electrocution hazard. The Cables need to be rerouted on certain UPS250IE, UPS300E, UPS500, UPS600, UPS750, and UPS900 Uninterrupted Power Supply (UPS) Systems.

AFFECTED PRODUCT

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Model	Identification Number
UPS 250I	CNM224, 225
UPS 300E	CPZ302-305
UPS 500	CSE103-109
UPS 600	CTX210-229
UPS 750	CPM147-151, 161, 184
UPS 900	CRY221

PARTS NEEDED

No parts needed.

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	1.0	0	0	0	0
NOTE: This is a 1.0-hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPOSITIONING THE PHASE A, B, AND C SYSTEM CABINET INPUT CABLES

MODELS INVOLVED - CERTAIN UPS250IE, UPS300E, UPS500, UPS600, UPS750, AND UPS900 UNINTERRUPTED POWER SUPPLY (UPS) SYSTEMS

Dear Caterpillar Product Owner:

The Phase A, B, and C System Cabinet Input Cables may have been routed incorrectly. This incorrect routing may cause wear and a consequent electrocution hazard. These cables need to be repositioned on the products listed below. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated March 12, 2004 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to March 12, 2004 Service Letter

Rework Procedure

NOTE: Certain serial numbered UPS models may have the Phase A, Phase B, and Phase C input power cables for F1, F2 and F3 of the Static Switch Contactor incorrectly routed. The cables may have been routed in such a manner as to be in direct contact with the bus work of the 1200A MCB contactor (Bypass Contactor). See Figure 1 and Figure 2. The area in question is located in the System Cabinet.

Illustration 1

Illustration 2

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Personal injury or death can result from high voltage.

When the flywheel is spinning, the following components are energized: the bus, the armature leads, and the flywheel armature fuses.

When Uninterruptible Power Supply (UPS) equipment must be in operation to make tests and/or adjustments, high voltage and current are present.

Improper test equipment can fail and present a high voltage shock hazard to its user.

Make sure that the testing equipment is designed for and correctly operated for the high voltage and high current tests that are being made.

When servicing or repairing UPS equipment, make sure all applicable capacitors are discharged.

Ensure that you have de-energized and electrically isolated the UPS system prior to performing the repair procedures.

Reference: For additional operational instructions and procedures, refer to the following publications: RENR2476, Systems Operations, Testing and Adjusting, "UPS250, UPS300, UPS500, UPS750, and UPS900 Uninterruptible Power Supply" and SEBU7464, Operation and Maintenance Manual, "UPS250, UPS300, UPS500, UPS600, UPS750, and UPS900 Uninterruptible Power Supply".

Once you have confirmed that the cables have been incorrectly routed, as shown in Figure 1 and Figure 2, you should de-energize and electrically isolated the UPS system prior to continuing with these instructions.
Inspect the cables for wear. If worn, replace, then with the UPS system de-energized and electrically isolated, reroute the input power cables as shown in Figure 3. There are no tools or parts required to perform this operation.
The dealer is required to provide a "digital picture" of the incorrectly routed cabling to the following contact. The picture should be sent via e-mail. Richard A. Bell, Caterpillar DPP, Product Service Engineer, (), Phone (770) 233-5773.