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


Contactor - Remove and Install

Usage:

UPS 250 APZ

Bypass Contactor ("K3") (Single-Module System)

Removal Procedure




Illustration 1g00842703

(1) Input Cables "K3"

(2) Contactor "K3"

(3) Output Cables "K3"

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

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

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

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

  1. 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.

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

  1. Remove three nuts from input power cables and remove cables (3) .

  1. Remove three nuts from output power cables and remove cables (1) .



    Illustration 2g00842716

    (4) "K3-6"

  1. Remove cable "K3-6" (4) .



    Illustration 3g00842751

    (5) "K3-A2"

  1. Remove cable "K3-A2" (5) .



    Illustration 4g00842756

    (6) "K13"

    (7) Diode "K3"

    (8) "K14"

  1. Remove cable and Diode "K13 - 14" (6 - 8) .

    Note: Make sure that the diode is not damaged or inverted.

  1. Disconnect two auxiliary input connectors. Connection 13 is orange and connection 14 is black.

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

  1. Remove four bolts.

  1. Remove contactor (2) from the cabinet.

Installation Procedure




Illustration 5g00842703

(1) Input Cables "K3"

(2) Contactor "K3"

(3) Output Cables "K3"

  1. Place contactor (2) in the cabinet.

  1. Install four bolts.



    Illustration 6g00842756

    (6) "K13"

    (7) "K3" Diode

    (8) "K14"

  1. Replace cable and Diode "K3 13-14" (6 - 8) .

    Note: Make sure that the arrow on the diode is pointing to "A1".




    Illustration 7g00842751

    (5) "K3-A2"

  1. Replace cable "K3 A2" (5) .



    Illustration 8g00842716

    (4) "K3-6"

  1. Replace cable "K3-6" (4) .

  1. Replace three output power cables and Torque the nuts to 41 N·m (30 lb ft).

  1. Replace three input power cables and Torque the nuts to 41 N·m (30 lb ft).

    Installation is complete.

Input Contactor ("K1")

Removal Procedure




Illustration 9g00859069

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

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

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

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

  1. 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.

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

  1. Remove three bolts (3) .

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

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

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

  1. Remove three bolts (5) .

  1. Remove four screws (4) .

  1. Remove contact (1) from the cabinet.

Installation Procedure




Illustration 10g00859069

  1. Install contact (1) in the cabinet.

  1. Install four screws (4) .

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

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

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

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

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

Output Contactor ("K2")

Removal Procedure




Illustration 11g00985506

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

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

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

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

  1. 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.

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

  1. Remove three bolts (1) .

  1. Remove three bolts (2) .

  1. Remove the two wires (3) for the auxiliary contact.

  1. Remove the brown wire and remove the orange wire that is located on the bottom of the contactor.

  1. Remove two coil wires. The coil wires have the following labels: "A1" (black) and "A2" (white).

  1. Remove four screws.

  1. Remove the contactor from the cabinet.

Installation Procedure




Illustration 12g00985506

  1. Install the contactor in the cabinet.

  1. Install four screws and tighten.

  1. Connect the coil wires. Wire "A1" is black and wire "A2" is white.

  1. Connect two auxiliary input connectors (3). Connection 13 is red and connection 14 is black.

  1. Install the brown wire and install the orange wire that is located on the bottom of the contactor.

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

  1. Install three bolts (1). Torque the bolts to 41 N·m (30 lb ft).

"S7" Settings

"S7" is a group of switches on the optional bypass contactor for adjusting the overcurrent trip point.




Illustration 13g00842928

Table 1
Bypass Contactor "K3"    
Long Time "L"     "I1" (1) = 1
"t1" (2) = 18 s or "D"    
Short Time "S"     "I2" (3) = 10
"t2" (4) = 0.5 s or "D" ("SW3" set to I > 12)    
Instantaneous Trip "I"     "I3" (5) = Off    
Control Switches (6)     Set to Man and 50    
Maintenance Bypass Contactor (1)    
Long Time "L"     "I1" (1) = 1
"t1" (2) = 18s or "D"    
Short Time "S"     "I2" (3) = "10"
"t2" (4) = 0.5s or "D" ("SW3" set to I > 12)    
Instantaneous Trip "I"     "I3" (5) = Off    
Control Switches (6)     Set to Man and 50    
Bypass Input Switch (1)    
Long Time "L"     "I1" (1) = 1
"t1" (2) = 18 s or "D"    
Short Time "S"     "I2" (3) = 10
"t2" (4) = 0.5s or "D" ("SW3" set to I > 12)    
Instantaneous Trip "I"     "I3" (5) = Off    
Control Switches (6)     Set to Man and 50    
( 1 ) Optional

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