- Uninterruptible Power Supply:
- UPS 120 (S/N: CNK1-UP)
- UPS 150 (S/N: CPC1-UP)
- UPS 250 (S/N: APZ294-UP)
- UPS 300 (S/N: CNJ312-UP)
- UPS 150 (S/N: CPC1-UP)
Introduction
The following information will aid the customer with the installation of the UPS (Single-Module System).
Acronyms
The following information is a list of the acronyms that may be used in this manual.
AC - Alternating Current
AWG - American Wire Gauge
ELV - Extra Low Voltage
EPO - Emergency Power Off
kVA - Kilovolt Ampere
LCD - Liquid Crystal Display
NEC - National Electric Code
NEMA - National Electrical Manufacturers Association
NFPA - National Fire Protection Association
SELV - Safety Extra Low Voltage
UPS - Uninterruptible Power Supply
VAC - Alternating Current Volt
Handling and Unpacking
Considerations for Installation
Note: Read this manual thoroughly before attempting to wire and/or operate the unit. Improper installation is the most significant cause of problems with start-up of the UPS.
Note: It is preferable to install the system in a restricted location in order to prevent access by unauthorized personnel. Refer to the diagrams in this manual.
- Proper planning will speed up the unloading of the UPS, location, and connection of the UPS.
- Use the shortest runs of cable that are possible. Consider any future additions when you are arranging the equipment.
- Avoid placing the unit in direct sunlight or near other heat sources.
- Be certain that the floor at the final location for the equipment and along the route to the site of the installation can support the weight of the UPS and the weight of any equipment that is handling the material. The UPS can weigh 5700 pounds.
- Verify that the floor is a minimum of 3000 psi concrete that is capable of supporting 325 pounds per square foot.
- The floor must be 2 to 3 degrees of being level. The floor should meet the load requirements of the anchor bolts.
- Plan the routing of the UPS in order to ensure that the UPS can move without a risk of damage through all aisles, through all doorways, and around all corners. If the UPS must be moved by an elevator, check the size of the door opening and the weight capacity of the elevator.
- The operating temperature range is from 0 °C (32 °F) to 40 °C (104 °F). Relative humidity must be less than 95 percent without condensation. Room ventilation is necessary. Make sure that the system that is used to control the environmental conditions in the room that contains the UPS can accommodate the load (BTU), even during power outages.
- A power outlet must be located within 9 m (30 ft) of the system. The outlet will be used in order to power the vacuum pump during maintenance and initial start-up.
Removing the Skid (Shipping)
Illustration 1 | g01125275 |
The cabinet is attached to 2 skids (1). The skids provide protection from shock and vibration.
Illustration 2 | g01125285 |
The skids (1) are attached to the cleats (cabinet) by 4 studs (5) with nuts and washers. Wood blocks (2,3,4) are inserted between the skids (1) and the base of the cabinet.
Illustration 3 | g01125282 |
A kickplate (6) is attached to the right side of the skids (1). The kickplate (6) protects the cabinet from damage by the fork lift while the cabinet is being moved. Refer to the following steps for removing the cabinet from the skids (1) .
- Remove the 4 screws (7) in order to remove the kickplate from the skid (1) .
Crushing Hazard. Use extreme care when handling this equipment due to the uneven weight distribution of the cabinets. Locate the center of gravity symbols. Lift the cabinets only in the locations that are shown. Test the lift and balance the cabinets before transporting the cabinets. Maintain a minimum tilt from vertical at all times. Use a suitable material handling device in order to move the cabinets to the final destination. If a forklift is used, it must have a minimum capacity of 3 tons. The forks must have a width of 520.70 mm (20.50 inches) but needs to be less than 609.60 mm (24.00 inches). Failure to adhere to this warning can result in personal injury or death. |
- Remove the screws that are securing the wood blocks to the skid.
Note: There are 2 screws per wood block.
- When the kickplate (6) is removed you will have access to the 2 studs (5) on the right side of the skid.
Refer to Illustration 2.
- Remove the 4 nuts and 4 washers from the studs (5) that secure the skids to the cleats (cabinet).
- Insert the forks from the fork lift under the cleat on the right side of the cabinet and lift the cabinet slightly until wood block (4) and wood block (3) can be removed.
NOTICE |
---|
Damage to the flywheel units can occur if the rotor for the flywheel is turning during the process of moving the unit. Do not move the flywheel units without the bearing retainers installed. |
Illustration 4 | g01125286 |
- Lower the cabinet onto the skid (1) .
- Insert the forks from the fork lift under the cabinet until both cleats (8) are supported by the forks.
Illustration 5 | g01125290 |
- Lift the cabinet slightly until wood block (2) can be removed.
- Lower the cabinet onto the skid (1) .
- Move the fork lift to the front of the cabinet and insert the forks underneath the cabinet.
Refer to Illustration 6 for the positioning of the fork lift.
Illustration 6 | g01125302 |
- Lift the cabinet away from the studs (5) .
- Remove the skids (1) .
- Lower the cabinet onto the cleats (8) .
The removal of the skid (shipping) is complete. Repeat the above procedure for any remaining cabinets.
Inspection of the Shipment
- Verify that all items have been received.
- If spare parts were ordered, verify that all of the parts have arrived.
- Check for loose connections or unsecured components in the cabinet.
- Check for any unsafe condition that may be a potential safety problem.
Site Preparation
Location of the Equipment
- Use a device that is suitable for moving the UPS to the final location. Exercise extreme caution because of the uneven weight distribution.
- Place the UPS in a reasonably clean environment that is free from dust. Air must be free to circulate around the cabinet. The UPS pulls the air through the front doors of the unit. The air circulates through the cabinet and out of the top of the cabinet for cooling purposes. Adequate ventilation, which includes air conditioning, must be provided in order to limit accumulation of heat in hot weather. The ambient temperature for the unit must be between -20 °C (-4 °F) to 40 °C (104 °F). There is a 0 °C (32 °F) requirement for the minimum ambient temperature for start-up of the unit. After the UPS has been running for a period of time, the UPS will stay warm enough in ambient temperatures as low as 0 °C (32 °F). However, bearing temperatures should be 20 °C (68 °F) or higher at start-up. Preheating of the rotor will be performed by the flywheel system if it is necessary for colder environments.
- Make sure that the floor can support the weight of the UPS and any other necessary equipment.
- A clearance of 914 mm (36 inches) is required from the front of the unit for service. The sides of the system can be placed against walls. However, several feet of additional space is preferable for improved airflow and easier cable connections. There is a minimum clearance of 610 mm (24 inches) that is needed between the top of the system and the ceiling in order to have proper airflow. See the illustrations that are located in Operation and Maintenance Manual, "Site Preparation".
- The cooling air exhausts at a rate of 2500 cfm. The height of the ceiling must be a minimum of 2.5 m (8 ft). The unit vents air out of the top. Loose ceiling tiles above the unit may be moved by the airflow.
- The system should not be operated in a sealed room or a sealed container. If the system must be operated in a sealed room adequate climate control must be provided. If the HVAC is necessary, then note that the heat that is generated from the system may exceed specifications when the system is protecting loads with low power factors or nonlinear loads.
- If you have purchased the UPS View software, you may need to plan for the installation of the RS-232 cable and/or RS-485 cable from the system to the local computer. When you are monitoring the UPS from a remote location with UPS View software, the following items may be needed: a modem, an Ethernet option, a phone line and local network connection.
- Install the appropriate cables in the system in order to support the remote notification and the option for monitoring the system that is chosen.
- The wire can be routed through the top or the bottom of the Bypass cabinet.
- An adequately sized neutral is required on the input and on the output of the system.
System Installation
NOTICE |
---|
The flywheel is shipped with bearing retainers that are installed in order to relieve the bearing of transient forces that may be encountered during shipping and handling. Do not attempt to remove the retainers or operate the unit until the unit is properly bolted to the floor anchors. The bearing retainers are to be removed only by Caterpillar authorized service personnel during the final inspection and before initial pre-startup. |
The system must be anchored to a foundation. The foundation should be a concrete slab that is fully cured. The slab should be poured with a minimum of 3000 psi concrete. Existing slabs should be free from cracks and seams in the vicinity of the installation. Refer to the ""Anchoring Cleats and Bolts" " section of this manual in order to determine the requirements for the positioning of the UPS on the slab. Refer to Illustration 19.
Anchor Bolts (Specifications)
Install the anchors in accordance with the manufacturer's specifications. The anchors must meet the following specifications:
Stud (Expansion)
- Length ... 152.40 mm (6.00 inch)
- Width ... 127.00 mm (5/8 inch)
- Embedment ... 101.60 mm (4.00 inch)
- Maximum Shear Load Capacity ... 7.6509 kN (1720.00 lb)
- Maximum Tensile Load Capacity ... 3.1138 kN (700.00 lb)
- Width ... 127.00 mm (5/8 inch)
When the thickness of the slab or the strength of the concrete is unknown consult with your Caterpillar Dealer.
Anchoring the System
- Locate the position for drilling the holes.
Crushing Hazard. Use extreme care when handling this equipment due to the uneven weight distribution of the cabinets. Locate the center of gravity symbols. Lift the cabinets only in the locations that are shown. Test the lift and balance the cabinets before transporting the cabinets. Maintain a minimum tilt from vertical at all times. Use a suitable material handling device in order to move the cabinets to the final destination. If a forklift is used, it must have a minimum capacity of 3 tons. The forks must have a width of 520.70 mm (20.50 inches) but needs to be less than 609.60 mm (24.00 inches). Failure to adhere to this warning can result in personal injury or death. |
- Drill the holes for the anchor bolts.
- Lift the system off the ground by using one of the items in the following list:
- A Fork Lift
- Pallet Jack
- A Fork Lift
NOTICE |
---|
Damage to the flywheel units can occur if the rotor for the flywheel is turning during the process of moving the unit. Do not move the flywheel units without the bearing retainers installed. |
- Remove the mounting cleats (10) .
Illustration 7 | g01126452 |
- Bolt the mounting cleats (10) to the floor.
- Slide the system onto the mounting cleats (10) .
- Bolt the system to the mounting cleats (10) .
The anchoring of the system is complete.
Seismic Requirements
The Flywheel is rated with a Zone 4 Seismic Rating. Compliance with this standard is based on calculations.
Seismic tie-down brackets are available as an option for areas with high seismic activity in order to secure the Single-Module System to the floor.
Wiring Considerations
AC Power Wiring Connections
This system must be installed with a disconnect switch that is supplied by the customer and has been rated for the output power. An additional service disconnect device must be installed for the input power when the device is required by local regulations and/or national regulations. |
Install the system per the National Electrical Code (NEC) and local codes. Verify the utility power. Make sure that the rating for the overcurrent protection that is for the input of the UPS will accommodate the input rating of the UPS.
Refer to the ""Connections" " Section of this manual for diagrams of the connections on the system that is being installed.
Determine the AC current for your system by using the following criteria: kVA, voltage and options. Also refer to the nameplates on the equipment for the model number, the rating, and the voltage.
Cable and sizes of conduit are based on the information from the Operation and Maintenance Manual, "Specifications" Section for your particular unit.
There are 2 galvanized steel panels that are removable. The panels are provided for the entry of cables into the UPS. One panel is located on top of the Bypass cabinet and the other panel is located on the bottom of the Bypass cabinet. Holes in the removable access plates should be cut in order to accommodate the size of the conduit. The plates should be removed prior to cutting the holes for the conduit in order to keep metal chips out of the cabinets. Input cables and output cables must be run in separate conduits.
NOTICE |
---|
After cutting holes in the access plates, be certain that no foreign matter remain inside the UPS. Make sure to block any additional holes in the plates through which foreign matter could later enter the UPS. |
All shielded cables, cables without shields, control wires without shields, and remote control wires without shields must be enclosed in individual separate conduits or a cable tray. Placing multiple cables in the same conduit with other control wires or power wires may cause system failure.
A ground wire must be run from the building ground to the ground point in the cabinet of the UPS. The conductor for the ground shall comply with the following conditions of installation:
- The insulated conductor for the ground must be sized in accordance with the National Electrical Code, local codes, and national codes. The ground must be installed as part of the circuit that supplies the unit or system.
- Ground the conductor for the ground that is described above to an earth ground at the service equipment. If the UPS is supplied by a system that is separate from the utility, ground the conductor at the transformer that is supplying power to the UPS or at the generator set.
The ground cable is connected to a plated copper bus bar. The bus bars are drilled for 3/8 inch hardware. The holes are spaced for 2 hole NEMA lugs with barrels.
Note: The Ground cable and lugs are supplied by the customer.
Make sure that all of the electrical outlet receptacles that are in the vicinity of the unit are grounded. Connect the conductors for the ground that are serving these receptacles to earth ground at the service equipment.
The connection terminals are drilled for 12.7 mm (.5 inch) hardware and spaced for 1 hole or 2 hole NEMA lugs. Connection terminals can be oriented for entering the cabinet from the top or the bottom. Doing so minimizes the number of bends. Space limitations require smaller parallel cables. When you use smaller cables, you reduce the risk of damage to the unit while you are pulling the cable.
Note: The lugs and the cable are supplied by the customer. Refer to the National Electrical Code (NEC) for the correct size of the following cables:power, ground and neutral. The torque for the wire connections is 61 N·m (45 lb ft).
NOTICE |
---|
The weight of the power cables must be adequately supported to avoid stress on the bus bars and lugs. |
The following three-phase power cables are connected in the Bypass cabinet:
- Input Cables
- Output Cables
- Ground Cables
- Neutral Cables
Note: Neutral cables are used only in four-wire systems.
Observe clockwise phase rotation of all power wiring. A qualified electrician should check the phase rotation.
The three-phase AC input and three-phase AC output cables are connected to a plated copper bus bar. The holes are spaced for 2-hole lugs with barrels.
Note: The tab on the plated copper bus bar must be inverted in order for the cable to be installed from the bottom of the cabinet.
Note: Overcurrent protection must be provided externally to the UPS. Overcurrent protection must conform to local codes and national codes.
NEC Requirements for the Sizing of the Conductors by the Customer
Note: Refer to the 2002 edition of the NFPA 70 National Electrical Code (NEC). Requirements of the local codes may vary from the requirements that are shown. Compliance with all codes is the responsibility of the installer.
Note: Use wire that is rated for 75 °C (167 °F).
25 °C (77 °F) 3 Conductors per Conduit (Three-Wire Product)     |
||||
---|---|---|---|---|
Number of Conductors per Phase     |
||||
Wire Size, AWG or kcmil     | UPS 120     | UPS 150     | UPS 250     | UPS 300     |
4     | NA     | NA     | NA     | NA     |
3     | NA     | NA     | NA     | NA     |
2     | NA     | NA     | NA     | NA     |
1     | NA     | NA     | NA     | NA     |
1/0     | NA     | NA     | NA     | NA     |
2/0     | 2     | NA     | NA     | NA     |
3/0     | 2     | NA     | NA     | NA     |
4/0     | 2     | NA     | NA     | NA     |
250     | 2     | 2     | 2     | 2     |
300     | 2     | 2     | 2     | 2     |
350     | 2     | 2     | 2     | 2     |
25 °C (77 °F) 4 Conductors per Conduit (Four-Wire Product)     |
||||
---|---|---|---|---|
Number of Conductors per Phase     | ||||
Wire Size, AWG or kcmil     | UPS 120     | UPS 150     | UPS 250     | UPS 300     |
4     | NA     | NA     | NA     | NA     |
3     | NA     | NA     | NA     | NA     |
2     | NA     | NA     | NA     | NA     |
1     | NA     | NA     | NA     | NA     |
1/0     | NA     | NA     | NA     | NA     |
2/0     | 2     | NA     | NA     | NA     |
3/0     | 2     | NA     | NA     | NA     |
4/0     | 2     | NA     | NA     | NA     |
250     | 2     | 2     | 2     | 2     |
300     | 2     | 2     | 2     | 2     |
350     | 2     | 2     | 2     | 2     |
40 °C (104 °F) 3 Conductors per Conduit (Three-Wire Product)     |
||||
---|---|---|---|---|
Number of Conductors per Phase     | ||||
Wire Size, AWG or kcmil     | UPS 120     | UPS 150     | UPS 250     | UPS 300     |
4     | NA     | NA     | NA     | NA     |
3     | NA     | NA     | NA     | NA     |
2     | NA     | NA     | NA     | NA     |
1     | NA     | NA     | NA     | NA     |
1/0     | NA     | NA     | NA     | NA     |
2/0     | 2     | NA     | NA     | NA     |
3/0     | 2     | NA     | NA     | NA     |
4/0     | 2     | NA     | NA     | NA     |
250     | 2     | 2     | 2     | 2     |
300     | 2     | 2     | 2     | 2     |
350     | 2     | 2     | 2     | 2     |
40 °C (104 °F) 4 Conductors per Conduit (Four-Wire Product)     |
||||
---|---|---|---|---|
Number of Conductors per Phase     | ||||
Wire Size, AWG or kcmil     | UPS 120     | UPS 150     | UPS 250     | UPS 300     |
4     | NA     | NA     | NA     | NA     |
3     | NA     | NA     | NA     | NA     |
2     | NA     | NA     | NA     | NA     |
1     | NA     | NA     | NA     | NA     |
1/0     | NA     | NA     | NA     | NA     |
2/0     | 2     | NA     | NA     | NA     |
3/0     | 2     | NA     | NA     | NA     |
4/0     | 2     | NA     | NA     | NA     |
250     | 2     | 2     | 2     | 2     |
300     | 2     | 2     | 2     | 2     |
350     | 2     | 2     | 2     | 2     |
25 °C (77 °F) 4 Conductors per Conduit (Four-Wire Product)     |
||||
---|---|---|---|---|
Number of Conductors per Phase     | ||||
Wire Size, AWG or kcmil     | UPS 120     | UPS 150     | UPS 250     | UPS 300     |
4     | NA     | NA     | NA     | NA     |
3     | NA     | NA     | NA     | NA     |
2     | NA     | NA     | NA     | NA     |
1     | NA     | NA     | NA     | NA     |
1/0     | NA     | NA     | NA     | NA     |
2/0     | 2     | NA     | NA     | NA     |
3/0     | 2     | NA     | NA     | NA     |
4/0     | 2     | NA     | NA     | NA     |
250     | 2     | 2     | 2     | 2     |
300     | 2     | 2     | 2     | 2     |
350     | 2     | 2     | 2     | 2     |
40 °C (104 °F) 3 Conductors per Conduit (Three-Wire Product)     |
||||
---|---|---|---|---|
Number of Conductors per Phase     | ||||
Wire Size, AWG or kcmil     | UPS 120     | UPS 150     | UPS 250     | UPS 300     |
4     | NA     | NA     | NA     | NA     |
3     | NA     | NA     | NA     | NA     |
2     | NA     | NA     | NA     | NA     |
1     | NA     | NA     | NA     | NA     |
1/0     | NA     | NA     | NA     | NA     |
2/0     | 2     | NA     | NA     | NA     |
3/0     | 2     | NA     | NA     | NA     |
4/0     | 2     | NA     | NA     | NA     |
250     | 2     | 2     | 2     | 2     |
300     | 2     | 2     | 2     | 2     |
350     | 2     | 2     | 2     | 2     |
Note: Use 75 °C (167 °F) wire.
Note: The recommended wire sizes are based on NFPA 70, National Electric Code (NEC) 2002 Edition. Local codes, national codes, or other applicable codes must also be observed.
Cable Connection
Refer to the ""Connections" " Section of this manual for diagrams of the connections on the system that is being installed.
Note: Make sure that the proper phase rotation is maintained at all times.
- Route the AC power cables through the holes that are for the entry of the cable. The holes are punched in the galvanized steel panel.
- Connect the three-phase AC input cables to the tab (bus) that is for power distribution. The tab (bus) is located in the bypass cabinet. Torque the cables to 61 N·m (45 lb ft).
- Connect the three-phase AC output cables to the tab (bus) that is for power distribution. The tab (bus) is located in the bypass cabinet. Torque the cables to 61 N·m (45 lb ft).
- Connect the ground cable to the plated copper tab (bus) that is located in the cabinet. Torque the ground cable to 61 N·m (45 lb ft).
Control Wiring
Refer to the ""Connections" " Section of this manual for diagrams of the connections on the system that is being installed.
NOTICE |
---|
Control wiring must be stranded and run in individual separate steel conduit. Control wiring must be separated from power wiring. Route control wiring as far away from power cables as possible to minimize Electro Magnetic Interface (EMI). |
Customer interfaces are accessible through dry contacts on the System Input/Output Board that is located on the left panel in the termination cabinet.
The UPS has a total of 6 input contacts and 6 form C output contacts that are available for use by the customer.
The UPS also accepts a serial connection for monitoring and control.
Terminal Connections (Control Wire)
Refer to the following steps in order to gain access to the dry contacts in the cabinet of the UPS:
- Open the door to the cabinet of the UPS.
- Remove the 2 screws (11) that are holding the cover (access panel) in place.
The dry contacts will be located on the System Input/Output Board (12) on the left panel.
Illustration 8 | g01148582 |
Illustration 9 | g01148586 |
(12) System Input/Output Board (13) System Input/Output Daughter Board |
System Input/Output Board
Illustration 10 | g01124905 |
(21) "J7" Remote Emergency Power Off (EPO) Contacts (22) "J14" Remote Input Contacts (23) "J6" Remote Output Contacts (24) "J12" Device Net (25) "J16" Modem DB 9 (26) "J10" Modem RJ45 (27) "J10a" Modem RJ11 (28) "J9" Ether Net (29) "J1" RS-232/RS-485 9 Pin Connector (30) "J8" UPSNET/CAN A (31) "J4" 24 VDC Power in |
System Input/Output Daughter Board
Illustration 11 | g01124913 |
(41) "J8" Backup UPS NET (42) "J5" Remote Panel Out (43) "J1" RS-485 (44) "J4" 24 VDC Power In |
Remote Emergency Power Off Contacts ("J7")
Illustration 12 | g01125023 |
(21) "J7" Remote Emergency Power Off (EPO) Contacts (48) Jumper |
Illustration 13 | g00741799 |
Remote Emergency Power Off Button |
The contacts for the Remote Emergency Power Off allow the customer to have a button that is installed remotely from the UPS in order to shut down the UPS in case of an emergency situation. The Remote Emergency Power Off Button is equivalent to the local Emergency Power Off Button. The Remote Emergency Power Off contacts (21) are located on the System Input/Output Board.
Terminal "J7" (21) has 2 sets of contacts that operate independently of each other.
Normally Open - Terminal 1 and Terminal 3
Normally Closed - Terminal 2 and Terminal 4
Note: The system is shipped with a Jumper (48) that is connected across the normally closed contacts. If the normally closed contacts are used remove the Jumper (48). If the normally open contacts (terminals 1 and 3) are used do not remove the Jumper (48) .
Table 7 can be used as a reference when you are connecting the control wiring in the UPS.
Control Wiring     | ||||
---|---|---|---|---|
Interface     | Connection in the Cabinet of the UPS     | Type of Connection     | Type of Wire     | Description     |
    | System Input/Output Board "J1"     | DB9 female connector     | 9-wire serial cable     | Monitoring Data (1)     |
    | System Input/Output Board "J9"     | RJ45 8-pin connector     | Category 5-24 AWG (without shield) 4-pair UTP     | Ethernet (1) (2)     |
    | System Input/Output Board "J14-7"     | Terminal Block     | 24 12 AWG Twisted Pair     | Input 1 Relay Coil (-) (1) (2) (3)     |
    | System Input/Output Board "J14-1"     | Terminal Block     | 24 12 AWG Twisted Pair     | Ground (1) (2) (3)     |
    | System Input/Output Board "J14-8"     | Terminal Block     | 24 12 AWG Twisted Pair     | Input 2 Relay Coil (-) (1) (2) (3)     |
    | System Input/Output Board "J14-2"     | Terminal Block     | 24 12 AWG Twisted Pair     | Ground (1) (3)     |
    | System Input/Output Board "J14-9"     | Terminal Block     | 24 12 AWG Twisted Pair     | Input 3 Relay Coil (-) (1) (2) (3)     |
    | System Input/Output Board "J14-3"     | Terminal Block     | 24 12 AWG Twisted Pair     | Ground (1) (2) (3)     |
    | System Input/Output Board "J14-10"     | Terminal Block     | 24 12 AWG Twisted Pair     | Input 4 Relay Coil (-) (1) (2) (3)     |
    | System Input/Output Board "J14-4"     | Terminal Block     | 24 12 AWG Twisted Pair     | Ground (1) (2) (3)     |
    | System Input/Output Board "J14-11"     | Terminal Block     | 24 12 AWG Twisted Pair     | Input 5 Relay Coil (-) (1) (2) (3)     |
    | System Input/Output Board "J14-5"     | Terminal Block     | 24 12 AWG Twisted Pair     | Ground (1) (2) (3)     |
    | System Input/Output Board "J14-12"     | Terminal Block     | 24 12 AWG Twisted Pair     | Input 6 Relay Coil (-) (1) (2) (3)     |
    | System Input/Output Board "J14-6"     | Terminal Block     | 24 12 AWG Twisted Pair     | Ground (1) (2) (3)     |
    | System Input/Output Board "J6-1"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 1 Normally Open (1) (2) (3)     |
    | System Input/Output Board "J6-2"     | Terminal Block     | 24 12 AWG Twisted Pair     | Common (1) (2) (3)     |
    | System Input/Output Board "J6-3"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 1 Normally Closed (1) (2) (3)     |
    | System Input/Output Board "J6-4"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 2 Normally Open (1) (2) (3)     |
    | System Input/Output Board "J6-5"     | Terminal Block     | 24 12 AWG Twisted Pair     | Common (1) (2) (3)     |
    | System Input/Output Board "J6-6"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 2 Normally Closed (1) (2) (3)     |
    | System Input/Output Board "J6-7"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 3 Normally Open (1) (2) (3)     |
    | System Input/Output Board "J6-8"     | Terminal Block     | 24 12 AWG Twisted Pair     | Common (1) (2) (3)     |
    | System Input/Output Board "J6-9"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 3 Normally Closed (1) (2) (3)     |
    | System Input/Output Board "J6-10"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 4 Normally Open (1) (2) (3)     |
    | System Input/Output Board "J6-11"     | Terminal Block     | 24 12 AWG Twisted Pair     | Common (1) (2) (3)     |
    | System Input/Output Board "J6-12"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 4 Normally Closed (1) (2) (3)     |
    | System Input/Output Board "J6-13"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 5 Normally Open (1) (2) (3)     |
    | System Input/Output Board "J6-14"     | Terminal Block     | 24 12 AWG Twisted Pair     | Common (1) (2) (3)     |
    | System Input/Output Board "J6-15"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 5 Normally Closed (1) (2) (3)     |
    | System Input/Output Board "J6-16"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 6 Normally Open (1) (2) (3)     |
    | System Input/Output Board "J6-17"     | Terminal Block     | 24 12 AWG Twisted Pair     | Common (1) (2) (3)     |
    | System Input/Output Board "J6-18"     | Terminal Block     | 24 12 AWG Twisted Pair     | Output 6 Normally Closed (1) (2) (3)     |
    | System Input/Output Board "J7-1"     | Terminal Block     | 24 12 AWG Twisted Pair     | Remote EPO Ground (1) (4)     |
    | System Input/Output Board "J7-2"     | Terminal Block     | 24 12 AWG Twisted Pair     | Remote EPO Ground (1) (4) (5)     |
    | System Input/Output Board "J7-3"     | Terminal Block     | 24 12 AWG Twisted Pair     | Remote EPO Normally Open (1) (4)     |
    | System Input/Output Board "J7-4"     | Terminal Block     | 24 12 AWG Twisted Pair     | Remote EPO Normally Closed (1) (4) (5)     |
( 1 ) | The Cables are not supplied. |
( 2 ) | Suitable for connections to NEC Class 2/SELV circuits only. |
( 3 ) | Programmable discrete signals. |
( 4 ) | Use NEC Class 1/ELV wiring methods. |
( 5 ) | Remove the factory jumper in order to use these terminals. |
Dry Contact Relays
All contacts can be configured with the UPS View software to indicate if certain conditions exist. The contacts are located on the System Input/Output Board.
Each input is intended to interface to a single-pole single-throw switch. The switch connects the pair of contacts or the switch disconnects the pair of contacts. The contacts that are user programmable have an operating parameter that is used to configure that contact.
The following list of functions can be assigned to the contacts for the remote input block by entering the parameter in the operating parameter for the associated remote input.
Table 8 shows the list of functions for the input contacts and Table 9 shows the default function.
List of Functions for the Input Contact     | ||
---|---|---|
Function     | Description     | |
0     | Disabled     | No function     |
1     | On Genset     | When the on genset function is activated, operational settings can be made for transient voltage detection, maximum input current, and walk-in rate.     |
2     | Remote Bypass     | Remote switch of UPS to bypass     |
3     | Remote Online     | Remote switch of the UPS to on-line condition only if no errors are active.     |
4     | Building Alarm 1     | An external alarm output contact is triggered.     |
5     | Building Alarm 2     | An external alarm output contact is triggered.     |
6     | Building Alarm 3     | An external alarm output contact is triggered.     |
7     | Building Alarm 4     | An external alarm output contact is triggered.     |
8     | Fire Alarm     | An external alarm output contact is triggered.     |
9     | Remote Silence     | Silences the buzzer, or a notice or alarm is active.     |
10     | Genset Breaker Open     | A "breaker open" message is shown when the input is activated. A "breaker closed" message is shown when the input is deactivated.     |
11     | Abnormal Room Temperature     | Prints a message indicating that the input is activated or deactivated.     |
12     | Synchronize to the External Source     |     |
13     | User Notice Message 1     | Used to configure the user text messages displayed by the UPS View software.     |
14     | User Notice Message 2     | Used to configure the user text messages displayed by the UPS View software.     |
15     | User Alarm Message 1     | Used to configure the user text messages displayed by the UPS View software.     |
16     | User Alarm Message 2     | Used to configure the user text messages displayed by the UPS View software.     |
17     | User Normal Message 1     | Generates event status     |
18     | User Normal Message 2     | Generates event status     |
19     | GSO Group A Open     | Monitor status of any installed Generator Set Start Module     |
20     | GSO Group B Open     | Monitor status of any installed Generator Set Start Module     |
21     | GSO Group C Open     | Monitor status of any installed Generator Set Start Module     |
22     | GSO Group D Open     | Monitor status of any installed Generator Set Start Module     |
23     | Remote Spindown     | Send UPS to bypass spindown     |
Default Function Assignments for Input Contacts     | ||
---|---|---|
Contact     | Function     | Description     |
1     | 1     | On Generator     |
2     | 2     | Remote switch from UPS to Bypass     |
3     | 3     | Remotely switch the UPS to On-line status. (1)     |
4     | 4     | Building Alarm 1     |
5     | 5     | Building Alarm 2     |
6     | 6     | Building Alarm 3     |
( 1 ) | This is done only if no errors are active. |
Table 10 shows the list of functions for the output contacts and Table 11 shows the default function.
List of Functions for Output Contact     | ||
---|---|---|
Function     | Description     | |
0     | No function     |     |
1-100     | Percent Energy (Flywheel)     | The flywheel has the programmed percentage of usable energy available and the system is on-line.     |
101     | Online (normal)     |     |
102     | On Bypass     |     |
103     | Flywheel Discharging     |     |
104     | A Notice condition on an Alarm condition is active.     |     |
105     | Alarm condition is active.     |     |
106     | Overload     |     |
107     | Cabinet over temperature     |     |
108     | External Alarm     | This is activated by programming remote inputs to any of the building alarms or the fire alarm functions.     |
109     | GSC unavailable     |     |
110     | Overload Bypass     | The system is in the Bypass mode because of an overload condition.     |
111     | Fusible Link Error     | The fusible link for the DC bus capacitor is open.     |
112     | Fan Error     |     |
113     | Run Genset     | Used with the Generator Set Start Module. Enables manual start.     |
114     | Pulsed Start Genset     | Used with the Generator Set Start Module. Enables manual start.     |
115     | Pulsed Stop Genset     | Used with the Generator Set Start Module. Enables manual stop.     |
116     | ATS Command     | Used with operating parameter ats command level. When in discharge and when total available system energy drops below preset level, the contact closes.     |
117     | Motoring     |     |
Default Function Assignments for Output Contacts     |     |     |
Contact     | Function     | Description     |
1     | 101     | Online (normal)     |
2     | 102     | On Bypass     |
3     | 103     | Flywheel Discharging     |
4     | 50     | Flywheel Percent Energy     |
5     | 104     | Notice condition or an Alarm condition is active     |
6     | 105     | Alarm condition is active     |
Bearing Retainers
NOTICE |
---|
The system must be anchored to the foundation prior to removing the bearing retainers. Removing the bearing retainers prior to anchoring the system will result in damage to the unit. |
Before the system is placed in operation, the shipping retainers must be removed and the operating retainers must be installed.
When the system is moved, the shipping retainers must be installed. These retainers protect the bearing cartridges. Store the retainers in a safe place for later use.
Removal of the Shipping Retainers
NOTICE |
---|
Only trained Caterpillar Dealer personnel should perform this procedure. |
Illustration 14 | g01148610 |
Exploded View of the Shipping Retainers (51) Two Bolts For The Upper Retainer (52) Upper Shipping Retainer (53) O-Ring (55) Lower Shipping Retainer (56) Two Bolts for the Lower Retainer |
- Remove three sheet metal panels. The panels are located inside the system.
- Loosen and remove two bolts (51) on the upper retainer (4). A quarter turn of rotation on each bolt should be used until the bolts are loose.
- By hand, pull out the retainer slowly.
Note: Do not use any tools in order to remove the retainer. This will damage the bearing cartridge.
- Store the retainer in a safe place for later use.
- Loosen and remove two bolts (56) on the lower retainer (55). A quarter turn of rotation on each bolt should be used until the bolts are loose.
- Slowly pull out the retainer.
Note: Do not use any tools in order to remove the retainer. This will damage the bearing cartridge.
- Store the retainer in a safe place for later use.
- Proceed to ""Installation of the Operating Retainers" ".
Installation of the Operating Retainer
NOTICE |
---|
Only trained Caterpillar Dealer personnel should perform this procedure. |
Illustration 15 | g01148627 |
(11) Screw (62) Sensor Assembly (63) O-ring (64) Hexagonal Bolt (65) Screw (66) Wheel (Rotor) (67) Brass Shim (68) Spacer (69) O-ring (70) Plug (71) Bearing Assembly (72) Thermocouple Gauge (73) Sleeve (Bearing Cartridge) (74) Spacer (75) Retaining Bolt (76) Mounting Hardware for the Drain (Charge) (77) Mounting Hardware (Drain(Charge)) (78) Drain (Charge) (79) Load Plate (80) Shims (Load Cell) (81) Load Cell and Base Plate Assembly (82) Hexagonal Bolt |
- Apply a small amount of 7M-7456 Bearing Mount Compound to the threads on bolt (75) .
- Install the following components: spacer (74) and bolt (75) .
- Torque bolt (75) to 38 N·m (28 lb ft).
- Install spacer (68) .
- Apply a small amount of 7M-7456 Bearing Mount Compound to the threads on bolt (64) .
- Install commutation sensor wheel (66) and bolt (64).
- Torque bolt (64) to 38 N·m (28 lb ft).
- Verify that the shims (load cell) are in place.
- Install assembly (load cell) (76,77,78,79,80,81) into the lower bearing.
- Install the 6 screws (82) through the load cell (81) into the bearing cartridge (73). Tighten screws (82) in increments of one quarter turns in order to allow the load cell to seat evenly. Tighten screws (82) to 27.12 N·m (20.00 lb ft).
- Apply a small amount of 6V-2055 High Vacuum Grease to O-ring (63) .
- Install the commutation sensor assembly (62) and three screws (61) .
Note: Make sure that the Rotor Position Sensor is positioned correctly. Refer to Systems Operation, Testing and Adjusting, "Rotor Position Sensor - Adjust" for the procedure for positioning the Rotor Position Sensor.
- Apply power to the vacuum pump. This requires an extension cable.
Note: The Multiple Module Units (300 Series) are set up for 230 VAC.
Note: Vacuum should be achieved as soon as possible. When the humidity is high and/or the flywheel was open for an extended time, the pump may require several hours in order to achieve the proper vacuum.
- Install thermistor sensing cables. Damage to the connector pins can result from improperly mated connectors.
- Install the three sheet metal panels.
Initial Setup Procedure
Single Input - No Switches
Note: This procedure should only be performed by service personnel that have been certified by Caterpillar. This procedure should be done after the system has been anchored into position and all wiring has been properly connected.
NOTICE |
---|
The following procedures must be complete before the initial startup of the system: Systems Operation, Testing and Adjusting, RENR2476, "Vibration Sensors Zeroes - Calibrate", Systems Operation, Testing and Adjusting, RENR2476, "Rotor Position Sensor - Adjust" and Systems Operation, Testing and Adjusting, RENR2476, "Rotor Position Sensor - Calibrate" |
- Apply facility power to the System Input Node.
Illustration 16 | g01142732 |
- Connect the System Output Node to the facility load circuits.
- Turn the UPS keyswitch to the "Online" position.
The system enters the "Bypassed-Auto Start" state and begins charging the flywheel. When the flywheel reaches a rate of 4000 RPM, the system shifts to the "Online" mode. The system is operational.
- Confirm that the UPS is in the "Online" mode by pressing the "Home" soft key on the User Interface while observing the status line on the LCD.
The installation of the UPS is complete. Contact Caterpillar Customer Support for system commissioning.
Single Input - 3 Switches
Note: This procedure should only be performed by service personnel that have been certified by Caterpillar. This procedure should be done after the system has been anchored into position and all wiring has been properly connected.
NOTICE |
---|
The following procedures must be complete before the initial startup of the system: Systems Operation, Testing and Adjusting, RENR2476, "Vibration Sensors Zeroes - Calibrate", Systems Operation, Testing and Adjusting, RENR2476, "Rotor Position Sensor - Adjust" and Systems Operation, Testing and Adjusting, RENR2476, "Rotor Position Sensor - Calibrate" |
- Apply facility power to the System Input Node.
Illustration 17 | g01142738 |
Illustration 18 | g01148108 |
- Connect the System Output Node to the facility load circuits.
- Confirm that the Bypass Switch (91) is open.
- Close the Input Isolation Switch (93) .
- Close the Output Isolation Switch (92) .
- Turn the keyswitch on the User Interface to the "Online" position.
The system enters the "Bypassed-Auto Start" state. The system begins charging the flywheel. When the flywheel reaches a rate of 4000 RPM, the system shifts to the "Online" mode. The system is operational.
- Confirm that the UPS is "Online" by pressing the "Home" soft key that is located on the User Interface panel and observing the status line on the LCD.
Installation Diagrams
Anchoring Cleats and Bolts
Illustration 19 | g01124641 |
Connections
3 Pole, 3 Wire, without Bypass
Illustration 20 | g01125357 |
3 Pole, 3 Wire, with Bypass
Illustration 21 | g01125362 |
3 Pole, 4 Wire, with Bypass
Illustration 22 | g01125368 |
4 Pole, 4 Wire, without Bypass
Illustration 23 | g01125370 |
4 Pole, 4 Wire, with Bypass
Illustration 24 | g01125371 |
Customer Connections Remote Control Wiring Diagram
Illustration 25 | g01125429 |