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


Power Supply - Remove and Install - Single or Dual Input without Maintenance Bypass

Usage:

UPS 250 APZ
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Illustration 1g00809802

(1) 24 VDC Power Supply 1

(2) 24 VDC Power Supply 2

Shutdown Procedure for Single or Dual Input without Maintenance Bypass

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NOTICE

If 24 VDC is still available, the service person should perform a "Control X" on the PC in order to brake the rotor. This will ensure that there is no power in the system upon shutdown.

  1. Turn the keyswitch for the System Cabinet to the Bypass position. Make sure that the system is in Bypass mode.

  1. Open the load circuit breaker downstream of the UPS system.

  1. Disconnect incoming power by opening the main circuit breaker that is located upstream from the UPS system.

  1. Allow the capacitor banks to bleed down for approximately 5 minutes in order to dissipate any residual energy in the bus, armature leads, and fuses.

Removal of the Power Supply

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    Illustration 2g00811061

  1. Open the door to the cabinet for the MMU or SMS in order to gain access to the door for the controller board (3) .

  1. Remove 3 screws (4) that secure the door for the controller board.
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    Illustration 3g00811076

  1. Remove the lower hose clamp (8) from the 24 VDC power supply module (9) .

  1. Remove the upper hose clamp (6) from the 24 VDC power supply module and remove the hose (7) .

  1. Remove 2 screws from the front of the power supply vent adapter (10) .

  1. Loosen the screw that is on the back of the power supply vent adapter (10) .

    Note: Do not remove the screw.

  1. Remove the power supply vent adapter (10) .
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    Illustration 4g00811094

  1. Label all the wires on the static switch interface board (11) .

  1. Disconnect the connector for the 24 VDC power supply from "J7" terminal (18) that is located at the rear of the board.

    Note: Terminal "J7" (18) can not be seen from the front of the unit.

  1. Disconnect the "APC" input/output connector from terminal "J1" (15) that is located at the rear of the board.

  1. Disconnect the External Thermistor connector from the terminal "J9" that is located at the rear of the board.

  1. Disconnect the "A" connector from terminal "J8" (12) .

  1. Disconnect the "A" connector from terminal "J6" (13) .

  1. Disconnect the "B" connector from terminal "J5" (14) .

  1. Disconnect the "B" connector from terminal "J4" (16) .

  1. Disconnect the "C" connector from terminal "J3" (17) .

  1. Disconnect the "C" connector from terminal "J2" (19) .

  1. Remove the 4 mounting screws and remove the board.

  1. Label the power cables on the terminals for the static switch input for the following phases: A, B and C. Label the power cables on the terminals for the static switch output for the following phases: A, B and C.

  1. Disconnect the power cables from each input terminal. Disconnect the power cables from each output terminal. Power cables must be disconnected from the following phases: A, B and C.

  1. Loosen the two mounting bolts at the top of the static switch module.

    Note: Do not remove the two mounting bolts.

  1. Remove the static switch.
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    Illustration 5g00811130

  1. Label all the wires on the assemblies for the power supply.

  1. Disconnect the red wire from terminal "J35" (25) on the "PWD".

  1. Disconnect the black wire from terminal "J46" (26) on the "PWD".

  1. Disconnect the red wire from terminal "J8" (24) on the "PWD".

  1. Disconnect the black wire from terminal "J40" (23) on the "PWD".

  1. Disconnect the black wire from terminal "J41" (33) on the "PWD".

  1. Disconnect "SK3" (27) from power supply 1.

  1. Disconnect "SK3" (29) from power supply 2.

  1. Disconnect the wires from the 2 capacitors that are located below the power supplies.

  1. Disconnect the 2 ground wires that are green from the chassis.

  1. Remove the top 2 mounting bolts (28) and (31) from the Power Supplies.

  1. Loosen the bottom 2 mounting bolts (30) and (31) from the Power Supplies.

    Note: Do not remove the 2 bottom mounting bolts.

  1. Remove the Power Supply.

Installation of Power Supply

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    Illustration 6g00811130

  1. Install the power supply onto the bottom 2 mounting bolts (30) and (31) .

  1. Insert the top 2 mounting bolts (29) and (32) and tighten all of the bolts.

  1. Connect the 2 green ground wires to the chassis and tighten.

  1. Connect the wires to the 2 capacitors that are located below the power supplies.

  1. Connect "SK3" (27) to power supply 1.

  1. Connect "SK3" (29) to power supply 2.

  1. Connect the black wire to terminal "J41" (33) on the "PWD".

  1. Connect the black wire to terminal "J40" (23) on the "PWD".

  1. Connect the red wire to terminal "J8" (24) on the "PWD".

  1. Connect the black wire to terminal "J46" (26) on the "PWD".

  1. Connect the red wire to terminal "J35" (25) on the "PWD".
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    Illustration 7g00811094

  1. Install the Static Switch. Install the input wires from both Power Supplies.

  1. Install the static switch in the cabinet. Tighten the 2 mounting bolts to 4.5 N·m (40.0 lb in).

  1. Connect the power cables to each of the input terminals for the following phases:A, B and C. Connect the power cables to each of the output terminals for the following phases:A, B and C. Tighten to 9.0 N·m (80.0 lb in).

  1. Install the interface board for the static switch onto the static switch. Attach with 4 mounting screws.

  1. Connect the "C" connector to terminal "J2" (19) .

  1. Connect the "C" connector to terminal "J3" (17) .

  1. Connect the "B" connector to terminal "J4" (16) .

  1. Connect the "B" connector to terminal "J5" (14) .

  1. Connect the "A" connector to terminal "J6" (13) .

  1. Connect the "A" connector to terminal "J8" (12) .

  1. Connect the External Thermistor connector to terminal "J9".

  1. Connect the "APC" input/output connector to terminal "J1" (15) .

  1. Connect the connector for the 24 VDC power supply to "J7" terminal (18) .
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    Illustration 8g00811076

  1. Install the power supply vent adapter (10) on the 24 VDC power supply module. Insert the 2 screws into the front of the power supply vent adapter and tighten.

  1. Tighten the screw on the rear of the power supply vent adapter (10) .

  1. Put a hose clamp (6) on the hose (5) that is for ventilation for the power supply. Install the hose on the upper air vent pipe and tighten.

  1. Attach and tighten the hose clamp (8) on the power supply vent adapter at the lower end of the hose (5) .
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    Illustration 9g00811061

  1. Close the door for the controller board (3). Insert the 3 screws (4) and tighten.

  1. Close the door for the cabinet of the MMU or the SMS.

Start up Procedure for Single or Dual Input without Maintenance Bypass

  1. Connect incoming power by opening the main circuit breaker that is located upstream from the UPS system.

  1. Close the load circuit breaker downstream of the UPS system.

  1. Turn the keyswitch on the System Cabinet to the "Online" position.

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