PRODUCT SUPPORT PROGRAM FOR INSTALLING SOFTWARE ON CERTAIN 120, 150, 250, 300, 301, 500, 600, 750, AND 900 MODEL UNINTERRUPTIBLE POWER SYSTEMS (UPS) Caterpillar


PRODUCT SUPPORT PROGRAM FOR INSTALLING SOFTWARE ON CERTAIN 120, 150, 250, 300, 301, 500, 600, 750, AND 900 MODEL UNINTERRUPTIBLE POWER SYSTEMS (UPS)

Usage:

REBE2717-00

25Feb2008


O-80
U-91
A-75
D-72

 
Before/After
  
  

PRODUCT SUPPORT PROGRAM FOR INSTALLING SOFTWARE ON CERTAIN 120, 150, 250, 300, 301, 500, 600, 750, AND 900 MODEL UNINTERRUPTIBLE POWER SYSTEMS (UPS)

4480 7620
PS42622
NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42622" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.


TERMINATION DATE

28Feb2010

PROBLEM

UPS Flywheel Bearing Monitoring Logic has been upgraded within the UPS software. The existing Uninterruptible Power System (UPS) software needs to be updated on certain UPS 120, 150, 250, 300, 301, 500, 600, 750, and 900 models.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
UPS 120  CNK00100-00101
UPS 150  CPC00100-00106, 108-116
UPS 250 APZ00225-00264, 270-290, 294, 296, 299-300, 302-316

CNM00224-00227, 235-236, 238
UPS 300 CNJ00176-00178, 180-271, 273-308, 312-351, 376-397

CPZ00302-00312, 315-319, 321, 323, 331, 351-361
UPS 301  CSY00192-00193, 196-200, 218
*******Group  2*******
UPS 500  CSE00103, 105-110, 113-115, 125-129, 131, 135-137, 140-143
UPS 600  CTX00210-00242, 260, 262-264, 266-285
*******Group  3*******
UPS 750  CPM00147-00151, 161-164
UPS 900  CRY00271-00323, 330-331, 333-341

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 2432252 SOFTWARE
1 2432253 SOFTWARE
1 2930782 SOFTWARE
1 2930783 SOFTWARE
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*******Group 2*******
1 2432252 SOFTWARE
1 2432253 SOFTWARE
1 2930782 SOFTWARE
1 2930783 SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*******Group 3*******
1 2432252 SOFTWARE
1 2432253 SOFTWARE
1 2930782 SOFTWARE
1 2930783 SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

Install new software. Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-100000 hrs,
0-132 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job for Group 1
An additional 1.0 hour will be allowed for N+1 units.

NOTE: Include N+1 in claim story when filing claim.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-100000 hrs,
0-132 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 2.0-hour job for Group 2
An additional 1.0 hour will be allowed for N+1 units.

NOTE: Include N+1 in claim story when filing claim.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-100000 hrs,
0-132 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 3.0-hour job for Group 3
An additional 1.0 hour will be allowed for N+1 units.

NOTE: Include N+1 in claim story when filing claim.



PARTS DISPOSITION

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


Rework Procedure


 
A new version of firmware for the UPS series has been released. The current UPS series requires periodic firmware upgrades to the existing system. These upgrades are essential in maintaining the performance requirements of the machine. The firmware may also incorporate an operational enhancement.

The service technician will need to obtain an electronic copy of the firmware update from the SIS web site prior to performing the actual upgrade. Please be aware there are two Special Instructions that detail the proper downloading procedure based on whether or not the technician has the "Autoloader Utility" available:

REHS4462- UPS Programming Autoloading Procedure
REHS4463- UPS Programming Manual Loading Procedure

The service technician will also be required to ensure that the UPS View 2.7 software is installed in the laptop computer that will be used to perform the upgrade. UPS View 2.7 is available as an upgrade on SIS Web. The firmware updates can only be executed by using the UPS View 2.7 version software.

The update for firmware should be performed at the time of commissioning procedure or for machines currently in operation at the next scheduled interval. The firmware version of a UPS can be determined by connecting the UPS to your laptop computer while utilizing the UPS View 2.7 software and performing a CTRL N function.
 
Bearing Temperature and Vibration Shutdown Logic (Upgrade description).

If the top or bottom bearing temperature reaches 115C and remains at 115C or above for a continuous 30-second time period, the UPS will initiate flywheel braking and will place the UPS in shutdown mode. In order to place the UPS back on-line, the bearing must be changed and the Bearing Install Data must be updated.

If the top or bottom bearing vibration reaches 0.8g and remains at 0.8g or above for a continuous 30-second time period, the UPS will initiate flywheel braking and will place the UPS in shutdown mode.

The UPS will ignore any Vacuum and Temperature errors during the braking period. If the 30-second timer expires while the flywheel is in Discharge Mode, the flywheel will begin braking after the UPS has finished the discharge period.

The flashfiles required for the rework are listed in Image 1.2.1. Download the flashfiles from SISweb. Flashfile version effectivity is 3.30 or greater for multi-module systems and 3.31 or greater for single module systems. Download the version listed or the most current version available.
Image1.2.1
 
 

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