UPS 1000S/ UPS 1200S Uninterruptible Power Supplys Caterpillar

Illustration 1	g01273699
(1) Breaker I/O, Top (2) Bolts supplied with Circuit Breaker (3) Circuit Breaker Rails (4) Wire Harness Connector (5) Wire Harness (6) Circuit Breaker I/O, Bottom (7) Spring Charge Status Indicator (8) Green "Breaker ON" Button (9) Red "Breaker OFF" Button (10) Breaker Status Indicator (11) Dip Switch Panel (12) Manual Charge Spring Lever

The Maintenance Bypass Circuit Breaker is a motor operated Circuit Breaker. The Maintenance Bypass Circuit Breaker is automatically activated by pressing one of the illuminated green buttons located in the Maintenance Bypass Cabinet. Automatic activation allows the UPS to control other Circuit Breakers in the system to put the system into and out of Maintenance Bypass without damaging the system.

The green "Breaker ON" button is covered by a metal plate to ensure that the breaker is not activated manually.

At the top of the Maintenance Bypass Circuit Breaker are three input connectors. These connectors connect to the three vertical bus bars coming from the input cable landing. There is one connector for each phase coming from the utility.

At the bottom of the Maintenance Bypass Circuit Breaker there are three output connectors. These connectors are connected to three output bus bars in the bottom of the cabinet behind the Maintenance Bypass Circuit Breaker.

On the right side of the Maintenance Bypass Circuit Breaker is a bank of connectors. These connections control the automatic switching of the Maintenance Bypass Circuit Breaker. There is also a bank of connectors on the left of the Maintenance Bypass Circuit Breaker that is unused.

On the front of the Maintenance Bypass Circuit Breaker is a bank of dip switches that set the automatic control behavior of the Maintenance Bypass Circuit Breaker. These switches are set at the factory and should never be changed.

The Maintenance Bypass Circuit Breaker weighs 61.2 kg (135 lb).

Removal

1. Perform steps in the Systems Operation, Testing and Adjusting, "Internal Component Preremoval Steps (Maintenance Bypass Cabinet)" in order to de-energize the system and gain access to internal components.

2. Disconnect the wire harness connector from the cabinet wiring.

3. Remove the 12 bolts that connect the connectors on the Maintenance Bypass Circuit Breaker to the three vertical bus bars on the top side of the Maintenance Bypass Circuit Breaker.

4. Remove the three lower L-shaped bus bars. Each bus bar contains four bolts for a total of 12 bolts.

5. Remove the four bolts on the bottom of the Maintenance Bypass Circuit Breaker that hold the Maintenance Bypass Circuit Breaker to the lower rail in the cabinet. The bolts are located at the bottom two corners of the Maintenance Bypass Circuit Breaker. Refer to bolt locations in Illustration 1.

6. Ensure that the Maintenance Bypass Circuit Breaker is supported so that the breaker will not drop during the next step.

7. Remove the four bolts on the top of the Maintenance Bypass Circuit Breaker that hold the Maintenance Bypass Circuit Breaker to the upper rail in the cabinet. Refer to Illustration 1.

   Note: The Maintenance Bypass Circuit Breaker weighs 61.2 kg (135 lb). It is recommended that two people and/or machinery is used to remove the Maintenance Bypass Circuit Breaker.

8. Remove the Maintenance Bypass Circuit Breaker from the cabinet.

9. Note the dip switch setting on the front of the Maintenance Bypass Circuit Breaker.

Installation

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Illustration 2	g01273733

1. Ensure the dip switch settings on the front of the new Maintenance Bypass Circuit Breaker match the old Maintenance Bypass Circuit Breaker. For the location see Illustration 1 and Illustration 2. If the dip switch settings cannot be determined, refer to Systems Operations, Testing and Adjusting, RENR7654, "Specifications".

2. Fabricate a support for the Maintenance Bypass Circuit Breaker.

   Due to the weight of the Maintenance Bypass Circuit Breaker, it is recommended that a support is used in order to aid the installer in securing the Maintenance Bypass Circuit Breaker to the cabinet rails.

3. Connect the wire harness to the right side of the Maintenance Bypass Circuit Breaker before installation into the cabinet.

   Note: Once the Maintenance Bypass Circuit Breaker is secured to the rails, there is not enough room to get to the wire harness.

4. Place the new Maintenance Bypass Circuit Breaker in the cabinet. Support the breaker in place.

5. Attach the Maintenance Bypass Circuit Breaker to the top rail. Use four of the eight bolts that are supplied. Insert the bolts through the front of the top four holes at the back corners of the Maintenance Bypass Circuit Breaker. Refer to Illustration 1

6. Tighten the top four bolts firmly.

7. If the bottom bolts cannot be installed, remove the support.

8. Attach the Maintenance Bypass Circuit Breaker to the lower rail. Use the other four bolts. Insert the bolts through the front of the bottom four holes at the back corners of the Maintenance Bypass Circuit Breaker.

9. Attach the three lower L-shaped bus bars. Insert four bolts with the head of the bolt facing toward the rear of the cabinet. Insert the four bolts through the following components: the output bus, the outputs of the Maintenance Bypass Circuit Breaker and the lower bus bars

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Illustration 3	g01273748
(60) Nut (61) Belleville Washer (62) Grade 8 Coated Steel Washer (63) Bus Bars (64) Bolt

10. Attach the washers and the nuts as indicated in Illustration 3.

    Note: In all cases the side of the belleville washer that curves inward should be placed facing the bus bar.

11. Attach the three vertical input bus bars to the three inputs of the Circuit Breaker. Insert four bolts in each bus bar, from the back side of the input bus bars.

12. Attach washers and nuts as indicated in Illustration 3.

13. Connect the harness wire connector to the cabinet wiring.

14. Tighten all 24 bus bar hex nuts to 150 N·m (110 lb ft).

    Note: Always tighten the hex nut, not the bolt.