A Disconnect Switch (Three-Phase AC) must be installed prior to the Generator Set Start Module. The size of the disconnect switch should be based on the specifications for the Generator Set Start Module.
The Caterpillar UPS can optionally be equipped with breakers (supply) that are wired to the output bus of the UPS in order to supply AC power to the Generator Set Start Module.
Note: The size of the conduit is based upon the size of the wire. The size of the conduit must be in accordance with the National Electrical Code (NEC) and other applicable codes.
The following types of conduit may be used: electrical metallic tubing, liquid-tight flexible metallic conduit and nonmetallic conduit. Use suitable waterproof fittings. The holes for the conduit must be punched into the cabinet. The size of the holes for the conduit must reflect the size of the waterproof fittings for a proper seal. Use care when you are making the holes in order to ensure that the interior components are not damaged, and that metal shavings are kept from contaminating the electrical connections and hardware. All metal shavings must be removed from the cabinet before power is applied.
The ground wire must be connected before continuing with the installation.
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Failure to connect the unit to a suitable grounding electrode can result in electrical shock and may cause injury or death. |
Use the same size of conductors and the same number of conductors for each polarity of DC wiring. A single 4/0 wire is the minimum that is required. Route the ground wire from the ground stud of the Generator Set Start Module to a suitable grounding electrode or equivalent. This must be done in accordance with national codes and local codes and ordinances.
Note: The maximum length for the ground wire should not exceed
Electrical Connections and Torque Values
Note: The recommended hardware requirements ensure successful installation and operation of the Generator Set Start Module.
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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:
Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged. |
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| Illustration 1 | g01071749 |
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(20) Output for the Negative DC Voltage
(21) Ground (22) Input from the Negative Pole of the Battery (23) Output for the Positive DC Voltage (24) Input from the Positive Pole of the Battery (25) Location for the Mounting of the Conduit | |
Refer to the section "Requirements for the Conduit" before installing the conduit for the 24 VDC wire.
The wires that are used to connect to the Generator Set Start Module must comply with the following guidelines:
Wire Size ... 4/0
Routing ... Wires must be routed through a conduit.
Size of Lugs ... 3/8 inch
Grade of Hardware ... Grade 5
Torque for Hardware ...
Install the Generator Set Start Module per the National Electrical Code (NEC) and other applicable codes. The size of the wire and the size of the conduit should be based on the specifications of the Generator Set Start Module.Class 1 wiring methods should be used.
DC Wiring to Starting Motor of the Generator Set
Note: This section pertains to Generator Sets without Batteries.
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To avoid personal injury from electrical shock, ensure that the negative battery cable is disconnected first. |
- De-energize the battery charger and lock out the battery charger for the batteries for the generator set.
- Remove the positive wires and the negative wires to the batteries from the battery charger.
- Remove the wires for the alternator charging circuit.
- Remove the negative battery cable from the negative battery terminal and the negative terminal of the starting motor.
- Remove the positive battery cable from the positive battery terminal and the positive terminal of the starting motor.
Note: These cables will not be reused during installation.
- Fabricate positive cables and negative cables in order to connect the Generator Set Start Module to the starter motor of the generator set.
Note: Make sure that the cable is long enough to reach from the starting motor to the Generator Set Start Module. Use 4/0 cable as a minimum with a 3/8 inch lug with hardware that has a rating of Grade 5. The maximum recommended cable length is
7.62 m (25.00 ft) from the generator set. Refer to the installation manuals for the generator set for maximum cable length. - Make sure that the ground cable is connected.
- Route the positive DC cable from the positive terminal of the starting motor to the positive bus of the Generator Set Start Module.
- Connect the cable to the positive bus of the Generator Set Start Module. Torque to
40.67 N·m (30.00 lb ft) - Connect the opposite end of the cable to the positive terminal of the starting motor. Torque to the value that is recommended by the manufacturer
- Route the negative DC cable from the negative terminal of the starting motor to the negative bus of the Generator Set Start Module.
- Connect the cable to the negative bus of the Generator Set Start Module. Torque to
40.67 N·m (30.00 lb ft) - Connect the opposite end of the cable to the negative terminal of the starting motor. Torque to the value that is recommended by the manufacturer
Note: This step refers to generator sets that are equipped with batteries.
DC Wiring to Starting Motor of the Generator Set
Note: This section pertains to Generator Sets with Batteries.
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To avoid personal injury from electrical shock, ensure that the negative battery cable is disconnected first. |
- De-energize the battery charger and lock out the battery charger for the batteries for the generator set. ,
- Disconnect the positive wires and the negative wires to the batteries from the battery charger.
- Disconnect the negative battery cable from the negative battery terminal and the negative terminal of the starting motor.
- Disconnect the positive battery cable from the positive battery terminal and the positive terminal of the starting motor.
Note: The positive battery cable will not be reused during installation.
- Fabricate positive cables and negative cables in order to connect the Generator Set Start Module to the starter motor of the generator set.
Note: Use 4/0 cable as a minimum with a 3/8 inch lug with hardware that has a rating of Grade 5. Maximum cable length is
7.62 m (25.00 ft) from the generator set. Refer to the manuals for the generator set for limitations on distance. Make sure that the cable is long enough to reach from the starting motor to the Generator Set Start Module. If a conduit is used, use a nonferrous conduit in order to avoid heating. - Make sure that the ground cable is connected.
- Route the positive DC cable from the positive terminal of the starting motor to the positive bus of the Generator Set Start Module.
- Connect the cable to the positive bus of the Generator Set Start Module. Torque to
40.67 N·m (30.00 lb ft) - Connect the opposite end of the cable to the positive terminal of the starting motor. Torque to manufacturer's specification
- Route the negative DC cable from the negative terminal of the starting motor to the negative bus of the Generator Set Start Module.
- Connect the cable to the negative bus of the Generator Set Start Module. Torque to
40.67 N·m (30.00 lb ft) - Connect the opposite end of the cable to the negative terminal of the starting motor. Torque to the value that is recommended by the manufacturer
Note: Perform the following steps in order to install the batteries for the generator set to the DC wiring for the Starting Power Paralleling Option.
- Fabricate cable. Use 4/0 cable as a minimum with a 3/8 inch lug with hardware that has a rating of Grade 5.
Note: Maximum total cable length is
7.62 m (25.00 ft) from the batteries to the starting motor. Refer to the manuals for the generator set for specifications on distance. Make sure that the cable is long enough to reach from the batteries to the Generator Set Start Module. Torque the bolts to40.67 N·m (30.00 lb ft) . If a conduit is used, use a nonferrous conduit in order to avoid heating. Refer to Illustration 1 when performing the following steps. - Route the DC cable from the positive terminal of the battery for the generator set to the positive bus for the battery input of the Generator Set Start Module. Refer to Illustration 1.
- Connect the cable to the positive bus that is for the input of the battery in the Generator Set Start Module. Torque the terminals to
40.67 N·m (30.00 lb ft) . Refer to Illustration 1. - Connect the opposite end of the cable to the positive terminal of the battery. Torque the bolt to the value that is recommended by the manufacturer.
- Reconnect the negative cable for the starting motor to the negative terminal of the battery. Torque to the value that is recommended by the manufacturer
- Reconnect the positive wires and negative wires from the battery charger to the batteries. Note: You may need to fabricate wires that are of the correct length in order to extend from the battery charger to the batteries.
- Energize the battery charger.
Note: This step refers to generator sets that are equipped with batteries.
Note: The wire for AC power is supplied by the customer.
The Caterpillar UPS can optionally be equipped with breakers (supply) that are wired to the output bus of the UPS in order to supply AC power to the Generator Set Start Module.
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| Illustration 2 | g00941033 |
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AC Supply and Wiring for the Customer Status Contacts (30) TB1 (31) Normally Open Output (Status) (32) COM Output (Status) (33) Normally Closed Output (Status) (34) AC Input Phase A (35) AC Input Phase B (36) AC Input Phase C (37) TB2 (38) Location for Mounting the Conduit | |
Refer to the section "Requirements for the Conduit" before installing the conduits for the wiring of the AC voltage.
Note: Penetration of the wall of the cabinet requires a female threaded fitting on the end of the conduit. The following paragraphs detail the requirements for the wiring for the AC supply and the wiring installation of the Customer Status Contacts. Refer to Illustration 2.
The wiring for the AC supply must meet the following specifications:
- Size ... 8 AWG
- Torque Value ...
4.97 N·m (44 lb in) - Composition of the Wire ... Copper
- Minimum Temperature Rating ...
75 °C (167.0000 °F) - Torque Value ...
The wires that are used to connect the Generator Set Start Module to the UPS must comply with the following guidelines:
- The wire must be run in a conduit.
- The wire must comply with all national ordinances and local ordinances.
Refer to Illustration 2 when performing the following steps.
- Make sure that the ground wire is connected.
- Connect the wire for the "a" phase of the incoming voltage to connector (34) that is located in the Generator Set Start Module.
- Connect the input wire for the "b" phase of the incoming voltage to connector (35) on the Generator Set Start Module.
- Connect the input wire for the "c" phase of the incoming voltage to connector (36) on the Generator Set Start Module.
- Connect the Customer Status Contacts.
Note: The wire for Customer Status Contacts must be routed in a conduit that is separate from AC input wiring. This wire must be isolated from the wiring for the AC voltage within the generator set start module.
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| Illustration 3 | g01057635 |
| Item | Part Number | Quantity | Description |
| Fuse (41) | 233-7661 | 2 | Fuse (.25 Ampere) |
| Diode (42) | 234-7920 | 1 | Diode |
| Capacitor (43) | 233-7653 | 2 | Capacitor |
| Relay (44) | 233-7660 | 1 | Relay
240 VAC 5 A DPDT Plug-in |
| Relay (45) | 233-7659 | 2 | Relay
24 VDC 10 A SPDT Plug-in |
| Contactor (46) | 235-5657 | 1 | Contactor |
| Fuse (47) | 233-7657 | 2 | Fuse (0.25 Ampere) |
| Transformer "T2" (48) | 235-5659 | 1 | Transformer |
| Board Assembly (49) | 235-6333 | 1 | Board Assembly (EMI Filter with Y2 Capacitor) |
| Circuit Breaker Assembly (50) | 233-7656 | 1 | Circuit Breaker Assembly (25 Ampere) |
| Bracket Assembly (51) | 235-5654 | 1 | Bracket Assembly |
| Shaft (52) | 235-5653 | 1 | Shaft |
| Handle (53) | 235-5652 | 1 | Handle |
| Transformer "T1" (54) | 235-5658 | 1 | Transformer |
| Switch (55) | 235-5660 | 1 | Switch - Temperature (Heat Sink) |
| Diode (56) | 235-5656 | 3 | Diode |