Installation of the Uninterruptible Power Supply (Single-Module System){4480} Caterpillar


Installation of the Uninterruptible Power Supply (Single-Module System){4480}

Usage:

UPS 250 APZ
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)

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 1g01125275

The cabinet is attached to 2 skids (1). The skids provide protection from shock and vibration.




Illustration 2g01125285

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 3g01125282

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) .

    ------ WARNING! ------

    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.

    ----------------------

  1. Remove the 4 screws (7) in order to remove the kickplate from the skid (1) .

  1. Remove the screws that are securing the wood blocks to the skid.

    Note: There are 2 screws per wood block.

  1. 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.

  1. Remove the 4 nuts and 4 washers from the studs (5) that secure the skids to the cleats (cabinet).


    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 4g01125286

  1. 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.

  1. Lower the cabinet onto the skid (1) .



    Illustration 5g01125290

  1. Insert the forks from the fork lift under the cabinet until both cleats (8) are supported by the forks.

  1. Lift the cabinet slightly until wood block (2) can be removed.

  1. Lower the cabinet onto the skid (1) .



    Illustration 6g01125302

  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.

  1. Lift the cabinet away from the studs (5) .

  1. Remove the skids (1) .

  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

  1. Verify that all items have been received.

  1. If spare parts were ordered, verify that all of the parts have arrived.

  1. Check for loose connections or unsecured components in the cabinet.

  1. 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)

When the thickness of the slab or the strength of the concrete is unknown consult with your Caterpillar Dealer.

Anchoring the System

    ------ WARNING! ------

    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.

    ----------------------

  1. Locate the position for drilling the holes.

  1. Drill the holes for the anchor bolts.


    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.


  1. Lift the system off the ground by using one of the items in the following list:

    • A Fork Lift

    • Pallet Jack




    Illustration 7g01126452

  1. Remove the mounting cleats (10) .

  1. Bolt the mounting cleats (10) to the floor.

  1. Slide the system onto the mounting cleats (10) .

  1. 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

------ WARNING! ------

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).

Table 1

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    

Table 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    

Table 3

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    

Table 4

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    

Table 5

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    

Table 6

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.

  1. 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.

  1. 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).

  1. 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).

  1. 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:

  1. Open the door to the cabinet of the UPS.



    Illustration 8g01148582



    Illustration 9g01148586

    (12) System Input/Output Board

    (13) System Input/Output Daughter Board

  1. 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.

System Input/Output Board




Illustration 10g01124905

(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 11g01124913

(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 12g01125023

(21) "J7" Remote Emergency Power Off (EPO) Contacts

(48) Jumper




Illustration 13g00741799

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.

Table 7
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.

Table 8
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    

Table 9
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.

Table 10
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        

Table 11
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 14g01148610

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

  1. Remove three sheet metal panels. The panels are located inside the system.

  1. 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.

  1. 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.

  1. Store the retainer in a safe place for later use.

  1. 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.

  1. Slowly pull out the retainer.

    Note: Do not use any tools in order to remove the retainer. This will damage the bearing cartridge.

  1. Store the retainer in a safe place for later use.

  1. Proceed to ""Installation of the Operating Retainers" ".

Installation of the Operating Retainer


NOTICE

Only trained Caterpillar Dealer personnel should perform this procedure.





Illustration 15g01148627

(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

  1. Apply a small amount of 7M-7456 Bearing Mount Compound to the threads on bolt (75) .

  1. Install the following components: spacer (74) and bolt (75) .

  1. Torque bolt (75) to 38 N·m (28 lb ft).

  1. Install spacer (68) .

  1. Apply a small amount of 7M-7456 Bearing Mount Compound to the threads on bolt (64) .

  1. Install commutation sensor wheel (66) and bolt (64).

  1. Torque bolt (64) to 38 N·m (28 lb ft).

  1. Verify that the shims (load cell) are in place.

  1. Install assembly (load cell) (76,77,78,79,80,81) into the lower bearing.

  1. 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).

  1. Apply a small amount of 6V-2055 High Vacuum Grease to O-ring (63) .

  1. 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.

  1. 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.

  1. Install thermistor sensing cables. Damage to the connector pins can result from improperly mated connectors.

  1. 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"





    Illustration 16g01142732

  1. Apply facility power to the System Input Node.

  1. Connect the System Output Node to the facility load circuits.

  1. 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.

  1. 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"





    Illustration 17g01142738



    Illustration 18g01148108

  1. Apply facility power to the System Input Node.

  1. Connect the System Output Node to the facility load circuits.

  1. Confirm that the Bypass Switch (91) is open.

  1. Close the Input Isolation Switch (93) .

  1. Close the Output Isolation Switch (92) .

  1. 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.

  1. 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 19g01124641

Connections

3 Pole, 3 Wire, without Bypass




Illustration 20g01125357

3 Pole, 3 Wire, with Bypass




Illustration 21g01125362

3 Pole, 4 Wire, with Bypass




Illustration 22g01125368

4 Pole, 4 Wire, without Bypass




Illustration 23g01125370

4 Pole, 4 Wire, with Bypass




Illustration 24g01125371

Customer Connections Remote Control Wiring Diagram




Illustration 25g01125429

Caterpillar Information System:

C9 Marine Engines and C9 Marine Generator Sets Alternator and Regulator
C9 Marine Engines and C9 Marine Generator Sets Alternator and Regulator
2004/08/01 An Improved Injection Actuation Pressure Sensor Is Now Used {1925}
EMCP3 Spare Analog Input Programming
EMCP3 Digital Input Programming
EMCP3 Component Location
3500 Engines for Caterpillar Built Generator Sets Prelube Pressure Switch
2004/08/01 An Improved Injection Actuation Pressure Sensor Is Now Used {1925}
3412E, C30 and C32 Marine Engines Engine Oil Pump - Install
3508B Industrial Engines Engine Oil Temperature Sensor
3508B, 3512B, and 3516B High Displacement Generator Sets Walk-Around Inspection
3412E, C30 and C32 Marine Engines Engine Oil Pump - Assemble
C9 Marine Engines and C9 Marine Generator Sets Electric Starting Motor
C15 and C18 Industrial Engines Water Temperature Regulator Housing - Remove and Install
C9 Marine Engines and C9 Marine Generator Sets Electric Starting Motor
C9 Marine Engines and C9 Marine Generator Sets Electric Starting Motor
2004/08/01 Maintenance Considerations for Engines in Landfill Applications {1000}
G3612 and G3616 Engines Product Description
TH31-C9I, TH31-C9P, TH31-C9T, TH35-C13I, TH35-C13T, TH35-C15I and TH35-C15T Petroleum Power Train Packages and TH31-E61 and TH35-E81 Petroleum Transmissions Transmission Bypass Valve (Transmission Oil Filter)
C18 Marine Generator Set Battery - Replace
3516C Locomotive Engine Safety Messages
C9 Marine Generator Set Engines Charging System - Test
Some Original Part Numbers Have Been Discontinued{1000, 7000, 7567} Some Original Part Numbers Have Been Discontinued{1000, 7000, 7567}
C9 Marine Engines CID 0175 FMI 03 Engine Oil Temperature open/short to +batt
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.