UPS 120, UPS 150, UPS 250 and UPS 300 Uninterruptible Power Supplies Caterpillar

Generator Set Start Module

Usage:

Show/hide table




Illustration 1	g00741402
Generator Set Start Module

System Description

The Generator Set Start Module provides redundant starting capability for the Caterpillar generator set. This option increases the generator's starting reliability. The Generator Set Start Module should be used as a redundant starting option to batteries.

Note: Caterpillar recommends the Generator Set Start Module in parallel to the Starting Power Paralleling Option. The Starting Power Paralleling Option provides isolation between the batteries and the Generator Set Start Module. The Generator Set Start Module can also be used with a separate dedicated starter.

The Generator Set Start Module provides auxiliary power to a starter. The auxiliary power comes from the Uninterruptible Power Supply (UPS).

Note: The auxiliary power can be up to 1000 amperes at 24 VDC.

When starting power is provided from the UPS flywheel, the standby generator will ensure a constant voltage source with the following characteristics:

independent of starting batteries
tolerant of wide temperature variances
monitored by the UPS

The Generator Set Start Module can be mounted on the floor or on a wall. When the specified cable and the provided connector are used, the length of the cable should not exceed 152.40 m (500.00 ft). The length of the cable between the Generator Set Start Module and the engine starter should not exceed 7.62 m (25.00 ft).

Specifications

Show/hide table

Table 1
Electrical Specifications
Nominal Voltage (Voltage Regulation)	24 VDC (+10% to -40%) at 0 − 1000 amperes DC
Current Rating	1000 amperes
Input Voltage	Up to 720 VAC (line to line)
Output Fusing	1000 amperes
Rated number of start cycles	5 cycles at 10 seconds per cycle

Show/hide table

Table 2
Physical Dimensions
Height	914.40 mm (36.0 inch)
Depth	310 mm (12.2 inch)
Width	610 mm (24 inch) ⁽¹⁾
Weight	181.44 kg (400 lb)
Distance from UPS	less than 152.4 m (500 ft)
Distance from engine starter	less than 7.62 m (25 ft)
Three-phase AC line from UPS ⁽²⁾	#6 AWG with 4 wires
DC cables	3/0 cable is the minimum size for a 1% maximum loss at 1000 amperes.
Indoor installation	NEMA 1 construction
Operating temperature	−20 °C (−4.0 °F) to 50 °C (122.0 °F)
Storage temperature	−25 °C (−13.0 °F) to 70 °C (158.0 °F)
Humidity	5% to 95% ⁽³⁾

Show/hide table

^( 1 )	This dimension includes the width of the heat sink.
^( 2 )	This item is not provided.
^( 3 )	non-condensable

Show/hide table

Table 3
Fuses
Location	Quantity
Bus Inductor Fuse for the Generator Set Start Module "F9"	1
The Generator Set Start Filter for the Generator Set Start Module ⁽¹⁾	2

Show/hide table

^( 1 )

UPS 250 model only

Information Plate

Show/hide table




Illustration 2	g00825894
Information Plate for the Generator Set Start Module

Receiving and Handling

Open the attached document that is located on the outside of the crate. This document will contain the instructions for removing the system and handling the system.

Site Preparation

Ensure that the floor can support the weight of the unit.
In order to service the unit, ensure that there is 1067.00 mm (42.00 inch) of clearance in front of the unit. Ensure that there are 160.27 mm (6.31 inch) of clearance on the unit's right side. This clearance is needed for the entry of the cable and for air circulation. Ensure that there are 236.47 mm (9.31 inch) of clearance on the unit's left side for air circulation.

Mounting

Clearance for the Door

Show/hide table




Illustration 3	g00821917
Requirements for the Clearance of the Door for the Generator Set Start Module

The Generator Set Start Module can be anchored to the floor or the Generator Set Start Module can be mounted on a wall. While the Generator Set Start Module is being installed, ensure that a radius of 518.16 mm (20.40 inch) is maintained for door swing. Refer to illustration 3.

Mounting on a Floor

Show/hide table




Illustration 4	g00821922
Clearance Requirements for the Generator Set Start Module for Mounting on the Floor (A) 50.80 mm (2.00 inch) (B) 236.47 mm (9.31 inch) (C) Holes for 5/16 inch hardware (D) 228.60 mm (9.00 inch) (E) 160.27 mm (6.31 inch) (F) 25.40 mm (1.00 inch) (G) 25.40 mm (1.00 inch) (H) 457.20 mm (18.00 inch) (I) 508.00 mm (20.00 inch) (J) 1067 mm (42.00 inch) (K) 904.75 mm (35.62 inch)

Inspect the location for the installation. Ensure that the floor meets the load requirements of the Generator Set Start Module. Ensure that there is sufficient space between the Generator Set Start Module and any obstructions. Refer to illustration 4.

Mounting on a Wall

Show/hide table




Illustration 5	g00822188
Dimensions for Mounting the Generator Set Start Module on a Wall (A) 63.50 mm (2.50 inch) (B) 381.00 mm (15.00 inch) (C) 555.75 mm (21.88 inch) (D) Mounting holes provisions for 5/16 inch mounting hardware (E) 331.72 mm (13.06 inch)

Inspect the location for the installation. Ensure that the wall meets the load requirements of the Generator Set Start Module. Ensure that sufficient clearance for the door is maintained.

The Generator Set Start Module has four mounting holes (D). These mounting holes are located on the back panel. These holes will accommodate 5/16 inch mounting hardware. Refer to illustration 5.

Electrical Connections

The Generator Set Start Module should be installed per the National Electrical Code (NEC) and other applicable codes. The size of the cable and the size of the conduit should be based on Start Module specifications. Class 1 wiring methods should be used.

Show/hide table




Illustration 6	g00822212
Generator Set Start Module Right Side View (1) Holes for Conduit for 24 VDC (1) Holes for Conduit for Control Power (1) Holes for Conduit for Ground (2) Entrance for the AC Voltage Bottom Entry Option or Side Entry Option (A) 309.88 mm (12.20 inch)

The holes must be drilled in the bottom of the lower access panel or the holes must be drilled in the side of the lower access panel (1, 2) in order to allow the cables to enter the Generator Set Start Module. Refer to illustration 6. The location of the holes will depend on the use of the following options: floor mounting option and wall mounting option. The input cables and the output cables must be routed in separate conduits.

Control Power (UPS 250)

Note: This section pertains to the UPS 250 only.

Show/hide table




Illustration 7	g00872251
Terminal Block for the Generator Set Start Module (3) Output To the Generator Set +24 VDC (4) Output To the Generator Set −24 VDC (5) Input From Generator Set +24 VDC (6) Input From Generator Set −24 VDC

Show/hide table

The inside compartments of the Generator Set Starting Module can contain the risk of electric shock or hazardous energy levels. Personal inuury can result from Electric Shock. Do not touch live electric parts.

The Control Power Signals for the Generator Set Start Module come from the connected generator and from the UPS. During starting attempts, either the battery for the generator set or the Caterpillar UPS will provide power for the Generator Set Control Circuits.

Use the following information to assemble the wires:

Wire size must be between #10 AWG and #14 AWG.
In order to connect the wire to the terminals, attach ring lugs (# 8 AWG) to the wire.
Maximum length of the wire is 15.24 m (50.00 ft).

24 VDC Output Cable

Show/hide table




Illustration 8	g00913187
Location for the connection of the 24 VDC Output Power Cable (7) AC Connector (B) 609.60 mm (24.00 inch) (C) 914.40 mm (36.00 inch) (D) Terminal Locations for the 24 VDC ( 3/8 inch hardware)

Show/hide table

Use the "+" terminal and the "−" terminal (D) in order to connect the cable for output power (24 VDC) to the generator. The "+" terminal and the "−" terminal (D) are located in the lower access compartment of the Generator Set Start Module. Refer to illustration 8.

Configure the cable in the following manner:

no smaller than 3/0
3/8 inch lugs and hardware
the maximum cable length from the generator 7.62 m (25.00 ft)
terminal torque 63.72 N·m (47 lb ft)
use nonferrous conduit

24 VDC Output Cable Connections (for Systems without a Starting Power Paralleling Module)

Note: This configuration requires a dedicated starting motor for the generator.

Show/hide table

To avoid personal injury from electrical shock, disconnect the AC Cable Connector that is located in the lower access compartment of the Generator Set Start Module before working on this equipment.

Show/hide table

Personal injury or death can result from high voltage.
When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.
Improper test equipment can fail and present a high voltage shock hazard to its user.
Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.
When servicing or repairing electric power generation equipment:

Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE.

Remove all fuses.

Make sure the generator engine is stopped.

Make sure all batteries are disconnected.

Make sure all capacitors are discharged.

Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.

Show/hide table

To avoid personal injury from electrical shock, ensure that the negative battery cable is disconnected first.

Disconnect the negative battery cable from the "-" terminal of the battery.

Disconnect the positive battery cable from the "+" terminal of the battery.

Route the DC cable from the Generator Set Start Module's "+" terminal to the "+" terminal of the dedicated starting motor. Tighten to 63.72 N·m (47.00 lb ft).

Route the DC cable from the Generator Set Start Module's "-" terminal to the "-" terminal of the dedicated starting motor. Tighten to 63.72 N·m (47.00 lb ft).

Reconnect the battery cables for the Generator Set.
Note: Connect the positive cable to the "+" terminal of the battery. Connect the negative cable to the "-" terminal of the battery.
Note: Battery voltage is now applied to the Generator Set Start Module.

Connect the AC Cable to the Generator Set Start Module. Refer to illustration 8.

The Connection of the Generator Set Start Module is complete.

The Cable for the UPS to Generator Set Start Module

Show/hide table




Illustration 9	g00869337
The AC Input Connector for the Generator Set Start Module (8) Cable Shield (9) Terminal lugs (#6 AWG wire) for 1/4 inch studs (10) AC input connector (11) "A" phase (12) No Connection (13) "B" phase (14) "C" phase

The cable that is used to connect to the UPS must comply with the following parameters. This cable is not included.

Maximum length of the cable is 152.4 m (500 ft).
Cable must be run in a conduit.
Cable must comply with all local ordinances.

Connect one end of the AC cable to the AC Input Connector (7) for the Generator Set Start Module. Refer to illustration 8.

Note: The penetration of the wall of the cabinet requires a female threaded fitting on the end of the conduit in order to accommodate strain relief.

The remaining end of the AC cable is connected to the AC output terminal blocks which are located inside the UPS. The UPS AC Output Terminals can be found in one of two locations. Refer to illustration 11 and illustration 10.

In order to connect the AC cable to the AC output terminal blocks, perform the following steps:

Strip a sufficient amount of cable shielding from the cable so that terminal lugs can be attached.

Attach terminal lugs to the cable. Terminal lugs should be sized for 1/4 inch studs.

Attach the cable to the Caterpillar UPS AC Output Terminals.

AC Output Terminal Location for the UPS 250

Show/hide table




Illustration 10	g00822965
AC Out terminal location for the UPS 250

On the UPS 250 (the 50 Hz and 60 Hz units), the AC output terminals are located on the AC capacitor bank panel. The ground connection is located on the Generator Set Start Module Inductor Panel.

AC Output Terminal Location for the UPS 300

Show/hide table




Illustration 11	g00822978
AC Output terminal location for the UPS 300

On the following models, the AC Output terminals and the ground terminal are located on the Generator Set Start Module Inductor Panel:

UPS 250 (50 Hz unit)
UPS 300 (60 Hz unit)
UPS 500 (50 Hz unit)
UPS 600 (60 Hz unit)
UPS 750 (50 Hz unit)
UPS 900 (60 Hz unit)

Grounding

The grounding wire should meet the following parameters:

# 6 AWG wire
a lug which will accommodate a 1/4 inch stud
maximum length of 7.62 m (25.00 ft)

Run a ground wire from the ground stud for the generator set to the Generator Set Start Module. The ground stud is located in the lower access compartment. Disconnect the AC ground from the upper cabinet. Insulate the AC ground from the upper cabinet.

Note: If there is a connection between the AC Input Connector and the ground, remove the connection before grounding the Generator Set Start Module to the Generator Set. Refer to illustration 8.

Disconnecting the Generator Set Start Module

Show/hide table

To disconnect the Generator Set Start Module from the power source for the UPS, unplug the AC cable connector. The Generator Set Start Module's AC cable connector (7) is located inside the Lower Access Compartment. Refer to illustration 8. Make sure that the generator set start module does not attempt to start the engine.

Starting Power Paralleling Option

Show/hide table




Illustration 12	g00932621
(1) Output (+) (2) Input 2 (+) (3) Input 1 (+) (4) Input/Output (-) (A) 609.60 mm (24.00 inch) (B) 531.88 mm (20.94 inch) (C) 762.00 mm (30.00 inch) (D) 684.28 mm (26.94 inch)

Installation Notes

The Starting Power Paralleling Option should be installed per the National Electrical Code (NEC) and all other applicable codes. The size of the cable and the size of the conduit should be determined by the specifications for the Starting Power Paralleling Option. Class 1 methods for wiring need to be used.

Install the Starting Power Paralleling Option in a clean environment that is free of dust.

When the Starting Power Paralleling Option is mounted on a wall, ensure that the wall can support the weight of the module (79.4 kg (175 lb)).

Show/hide table




Illustration 13	g00932672
(E) 457.20 mm (18.00 inch) (F) 76.20 mm (3.00 inch) (G) 793.75 mm (31.25 inch) (H) 11.18 mm (0.44 inch)

The Starting Power Paralleling Option has four mounting brackets that are located on the back of the module. These four mounting brackets have provisions for 5/16 inch mounting hardware.

Show/hide table




Illustration 14	g00932673
(I) 598.93 mm (23.58 inch)

Ensure that a radius of 598.93 mm (23.58 inch) is maintained for the swing of the door. Ensure that there is 431.8 mm (17 inch) of front clearance.

Holes must be punched in the module in order to accommodate the entry of the cable and the points of exit. The location of these holes will depend on the location of the Starting Power Paralleling Option with respect to the Generator Set and the Generator Set Start Module.

Input 1 and Input 2 are interchangeable. Input 1 and Input 2 can be used for the Generator Set Start Module. Input 1 and Input 2 can be used for the Batteries for Generator Set.

DC Cable Connections (Generator Set Start Module to Starting Power Paralleling Option)

Show/hide table

Personal injury or death can result from high voltage.
When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.
Improper test equipment can fail and present a high voltage shock hazard to its user.
Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.
When servicing or repairing electric power generation equipment:

Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE.

Make sure the generator engine is stopped.

Make sure all batteries are disconnected.

Make sure all capacitors are discharged.

Route the DC cable from the terminal at the Generator Set Start Module "+" to Input 1 of the Positive Bus of the Starting Power Paralleling Option. Tighten to 63.72 N·m (47 lb ft).

Route the DC cable from the "-" terminal of the Generator Set Start Module to the Input/Output of the Negative Bus of the Starting Power Paralleling Option. Tighten to 63.72 N·m (47 lb ft).

DC Cable Connections (Starting Motor for the Generator Set to Starting Power Paralleling Option)

Show/hide table

To avoid personal injury from electrical shock, ensure that the negative battery cable is disconnected first.

Disconnect the negative battery cable from the "-" terminal of the battery.

Disconnect the positive battery cable from the "+" terminal of the battery and the "+" terminal of the starting motor.
Note: This cable will not be reused.

Fabricate 2 cables. Use 3/0 cable as a minimum with 3/8 inch hardware (Grade 8) for the lugs. Maximum cable length is 7.62 m (25 ft) from the generator set. Tighten to 63.72 N·m (47 lb ft). If a conduit is used, use a conduit that is nonferrous in order to avoid heating. Ensure that the cable is long enough to reach from the starting motor to the Starting Power Paralleling Option.

Route the DC cable from the "+" terminal of the starting motor to the Positive bus of the Starting Power Paralleling Option. Tighten to 63.72 N·m (47 lb ft).

Install the DC cable and route the DC cable from the "-" terminal of the starting motor to the negative bus of the Starting Power Paralleling Module. Tighten to 63.72 N·m (47 lb ft).

DC Cable Connections (Batteries for the Generator Set to Starting Power Paralleling Option)

Fabricate cable. Use 3/0 cable as a minimum with 3/8 inch hardware (Grade 8) for the lugs. Maximum cable length is 7.62 m (25 ft) from the generator set. Tighten to 63.72 N·m (47 lb ft). If a conduit is used, use a conduit that is a nonferrous type in order to avoid heating. Ensure that the cable is long enough to reach from the starting motor to the Starting Power Paralleling Option.

Route the DC cable from the "+" terminal of the battery of the Generator Set to Input 2 of the Positive bus of the Starting Power Paralleling Module. Tighten to 63.72 N·m (47 lb ft).

Grounding

Fabricate the Cable.
Use #6 AWG wire
Attach a lug that will accommodate a 1/4 inch stud.
The maximum length of the wire should not exceed 3.05 m (10 ft).

Route the ground cable from the ground stud of the Starting Power Paralleling Module to the Ground stud of the Generator Set.

Tighten the ground stud to 63.72 N·m (47.00 lb ft).

Reconnect the battery cables for the Generator Set.
Connect the positive cable to the positive terminal of the battery. Connect the negative cable to the negative terminal of the battery.

Connect the AC cable for the Generator Set Start Module to the Generator Set Start Module. Refer to illustration 8.
The connection of the Starting Power Paralleling Module is complete.

Reference Materials

Symbols

There may be several specific symbols on the Generator Set Start Module. Refer to Operation and Maintenance Manual, "Symbols" for the related information.