Uninterruptible Power Supply (UPS) 250 Caterpillar

Bypass Contactor (K3)

Removal Procedure

Illustration 1	g00689659
(1) Bypass Contactor (K3) (2) Bolts (3) Screws (4) Bolts (5) Auxiliary Input Connectors

1. Place the system in bypass mode by turning the keyswitch to the Bypass position.

2. Isolate the system from the load by closing the bypass circuit breakers.

3. Open the circuit breaker for the output of the system.

4. Open the AC circuit breaker for the input of the system.

5. Allow the capacitor banks to bleed down for approximately 5 minutes.

   Note: When the flywheel is spinning, the following components are energized: the bus, the armature leads and the fuses. Accomplish the procedure as quickly as possible. During the procedure, the rotor is spinning on the bottom bearing.

6. Label all the input wires and all of the output wires.

7. Remove three bolts (2) .

8. Remove three bolts (4) .

9. Disconnect two auxiliary input connectors (5). Connection 13 is orange and connection 14 is black.

10. Disconnect the two input connectors. The connections are located on top of contact (1). Connection A1 is black and connection A2 is white.

11. Remove four screws (3) .

12. Remove contact (1) from the cabinet.

Installation Procedure

Illustration 2	g00689659
(1) Bypass Contactor (K3) (2) Bolts (3) Screws (4) Bolts (5) Auxiliary Input Connectors

1. Place contact (1) in the cabinet.

2. Install four screws (3) .

3. Connect the two input connectors. The connections are located on top of contact (1). Connection A1 is black and connection A2 is white.

4. Connect two auxiliary input connectors (5). Connection 13 is orange and connection 14 is black.

5. Install three bolts (4). Torque the bolts to 41 N·m (30 lb ft).

6. Install three bolts (2). Torque the bolts to 41 N·m (30 lb ft).

Input Contactor (K1)

Removal Procedure

Illustration 3	g00689686
(1) Input Contactor (K1) (2) Coil Wires (3) Bolts (4) Screws (5) Bolts (6) Wires (7) Auxiliary Input Connectors

1. Place the system in bypass mode by turning the keyswitch to the Bypass position.

2. Isolate the system from the load by closing the bypass circuit breakers.

3. Open the circuit breaker for the output of the system.

4. Open the AC circuit breaker for the input of the system.

5. Allow the capacitor banks to bleed down for approximately 5 minutes.

   Note: When the flywheel is spinning, the following components are energized: the bus, the armature leads and the fuses. Accomplish the procedure as quickly as possible. During the procedure, the rotor is spinning on the bottom bearing.

6. Label all the input wires and all of the output wires.

7. Remove three bolts (3) .

8. Disconnect two coil wires (2). The connections are located on top of contact (1). Connection A1 is black and connection A2 is white.

9. Disconnect two wires (6). The wires are located on the bottom of contactor (1). The wires are brown and orange.

10. Disconnect two auxiliary input connectors (7). Connection 13 is brown and connection 14 is black.

11. Remove three bolts (5) .

12. Remove four screws (4) .

13. Remove contact (1) from the cabinet.

Installation Procedure

Illustration 4	g00689686
(1) Input Contactor (K1) (2) Coil Wires (3) Bolts (4) Screws (5) Bolts (6) Wires (7) Auxiliary Input Connectors

1. Install contact (1) in the cabinet.

2. Install four screws (4) .

3. Install three bolts (5). Torque the bolts to 41 N·m (30 lb ft).

4. Connect two auxiliary input connectors (7). Connection 13 is brown and connection 14 is black.

5. Connect two wires (6). The connections are located on the bottom of contactor (1). The wires are brown and orange.

6. Connect two coil wires (2). The connections are located on top of contact (1). Connection A1 is black and connection A2 is white.

7. Install three bolts (3). Torque the bolts to 41 N·m (30 lb ft).

Output Contactor (K2)

Removal Procedure

Illustration 5	g00689709
(1) Auxiliary Input Connectors (2) Bolts (3) Input Connectors (4) Wires for the EMI Filter (5) Output Contactor (K2) (6) Screws (7) Bolts (8) Input Wires

1. Place the system in bypass mode by turning the keyswitch to the Bypass position.

2. Isolate the system from the load by closing the bypass circuit breakers.

3. Open the circuit breaker for the output of the system.

4. Open the AC circuit breaker for the input of the system.

5. Allow the capacitor banks to bleed down for approximately 5 minutes.

   Note: When the flywheel is spinning, the following components are energized: the bus, the armature leads and the fuses. Accomplish the procedure as quickly as possible. During the procedure, the rotor is spinning on the bottom bearing.

6. Label all the input wires and all of the output wires.

7. Remove three bolts (7) .

8. Remove three bolts (2) .

9. Disconnect EMI filter wires (4) from contact (5) .

10. Disconnect input wires (8) from contact (5) .

11. Disconnect two auxiliary input connectors (1). Connection 13 is red and connection 14 is black.

12. Disconnect two input connectors (3). The connections are located on top of contact (5). Connection A1 is black and connection A2 is white.

13. Remove four screws (6) .

14. Remove contact (5) from the cabinet.

Installation Procedure

Illustration 6	g00689709
(1) Auxiliary Input Connectors (2) Bolts (3) Input Connectors (4) Wires for the EMI Filter (5) Output Contactor (K2) (6) Screws (7) Bolts (8) Input Wires

1. Install contact (5) in the cabinet.

2. Install four screws (6) .

3. Connect two input connectors (3). The connections are located on top of contact (5). Connection A1 is black and connection A2 is white.

4. Connect two auxiliary input connectors (1). Connection 13 is red and connection 14 is black.

5. Connect input wires (8) to contact (5) .

6. Connect EMI filter wires (4) to contact (5).

7. Install three bolts (2). Torque the bolts to 41 N·m (30 lb ft).

8. Install three bolts (7). Torque the bolts to 41 N·m (30 lb ft).