UPS 250, UPS 300, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supply Caterpillar

Illustration 1	g00808657
(1) "J16 System I/O Connector #2" (2) "J15 AC Interface Board" (3) "J14 System I/O Connector #1" (4) "J19 DC Interface" (5) "J18 Fan Interface" (6) "J17 User Interface" (7) "J13 DC-DC Power Supply" (8) "J1 24 VDC Power In" (9) "J8 Static Switch Interface Board" (10) "J28 SIO Lite IDC" (11) "J27 SIO Extra RS232" (12) "J2 Skip Interface Board #1 (Flywheel)" (13) "J3 Skip Interface Board #2 (Flywheel)" (14) "J4 Skip Interface Board #3 (Flywheel)" (15) "J5 Skip Interface Board #A (Utility)" (16) "J6 Skip Interface Board #B (Utility)" (17) "J7 Skip Interface Board #C (Utility)" (18) "J9 Field Coil Driver Board" (19) "J10 Flywheel Interface Connector #2" (20) "J11 Flywheel Interface Connector #1" (21) "J12 Gen Set Start Controller"

Illustration 2	g00812337
(20) Controller Board

Removal Procedure

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. Disconnect the input connector from terminal "J1".

8. Disconnect the cable connector from "J27" to "J28".

9. Disconnect the cable connector "1" from terminal "J2".

10. Disconnect the cable connector "2" from terminal "J3".

11. Disconnect the cable connector "3" from terminal "J4".

12. Disconnect the cable connector "A" from terminal "J5".

13. Disconnect the cable connector "B" from terminal "J6".

14. Disconnect the cable connector "C" from terminal "J7".

15. Disconnect the cable connector for the static switch from terminal "J8".

16. Disconnect the cable connector for the "field coil driver" from terminal "J9".

17. Disconnect the connector for "flywheel interface number 2" from terminal "J10".

18. Disconnect the connector for "flywheel interface number 1" from terminal "J11".

19. Disconnect the connector for the "diesel start driver" from terminal "J12".

20. Disconnect the "24 VDC regulation" connector from terminal "J13".

21. Disconnect the "I/O" connector from terminal "J14".

22. Disconnect the "AC input" connector from terminal "J15".

23. Disconnect the "I/O" connector from terminal "J16".

24. Disconnect the "user interface" connector from terminal "J17".

25. Disconnect the "fan interface" connector from terminal "J18".

26. Disconnect the "24 VDC input" connector from terminal "J19".

27. Remove the board from the nine plastic mounting spacers.

Installation Procedure

1. Install the new board.

2. Connect the "24 VDC input" connector to terminal "J19".

3. Connect the "fan interface" connector to terminal "J18".

4. Connect the "user interface" connector to terminal "J17".

5. Connect the "I/O" connector to terminal "J16".

6. Connect the "AC input" connector to terminal "J15".

7. Connect the "I/O" connector to terminal "J14".

8. Connect the "24 VDC regulation" connector to terminal "J13".

9. Connect the connector for the "diesel start driver" to terminal "J12".

10. Connect the connector for the "flywheel interface number 1" to terminal "J11".

11. Connect the connector for the "flywheel interface number 2" to terminal "J10".

12. Connect the cable connector for the "field coil driver" to terminal "J9".

13. Connect the cable connector for the static switch to terminal "J8".

14. Connect the cable connector "C" to terminal "J7".

15. Connect the cable connector "B" to terminal "J6".

16. Connect the cable connector "A" to terminal "J5".

17. Connect the cable connector "3" to terminal "J4".

18. Connect the cable connector "2" to terminal "J3".

19. Connect the cable connector "1" to terminal "J2".

20. Connect the cable connector between "J27" and"J28".

21. Connect the input connector to terminal "J1".

22. Calibrate the DC voltage. Refer to Testing and Adjusting, "DC Voltage - Calibrate".

23. Calibrate the AC voltage and the AC current. Refer to Testing and Adjusting, "AC Voltage - Calibrate".

24. Calibrate the hall effect sensors. Refer to Testing and Adjusting, "Flywheel Telemetry - Calibrate".

25. Calibrate the Vibration Sensor.

26. Proceed to the calibration of RPS.