UPS 1000S/ UPS 1200S Uninterruptible Power Supplys Caterpillar

Illustration 1	g01273699
(1) Breaker I/O, Top (3) (2) Bolts supplied with Circuit Breaker (8) (3) Circuit Breaker Rails (4) Wire Harness Connector (5) Wire Harness (6) Circuit Breaker I/O, Bottom (3) (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 Input/Output Cabinet contains an Input Circuit Breaker and an optional Output Circuit Breaker.

The Input Circuit Breaker is a motor operated circuit breaker.

The Output Circuit Breaker, if present, may or may not be a motor operated circuit breaker, depending on the options.

The breakers are automatically activated by pressing one of the illuminated green buttons that are located in the Maintenance Bypass Cabinet.

Automatic activation allows the UPS to control the circuit breakers in the system. Automatic activation allows the system to be put into and out of Maintenance Bypass without damaging the system.

There are manual switches located on the front of the circuit breaker, but the switches should not be used as damage to the system can occur. The green Breaker "ON" button is covered by a metal plate to ensure that the breaker is not activated manually.

At the top of each circuit breaker are three input connectors. These connectors connect to the vertical bus bars coming from the input and output cable landings. There is one connector for each phase coming from the utility.

The bottom of each circuit breaker contains three output connectors. These connectors are connected to three output bus bars that are located in the bottom of the cabinet behind the breaker.

The right side of each circuit breaker contains a bank of connectors. These connections control the automatic switching of the breaker. There is also a bank of connectors on the left of each breaker that is unused.

The front of the circuit breaker contains a bank of dip switches that set the automatic control behavior of the breaker. These switches are coordinated with the rest of the UPS system. These switches should never be changed.

Refer to the following information for the weight of the K1 Circuit Breaker and the K5 Circuit Breaker.

K1 ... 61.2 kg (135 lb)

K5 ... 61.2 kg (135 lb)

Removal

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

2. Disconnect the connectors to the Breaker Bell Alarm Supervisor Board that is located on the vertical frame at the front bottom of the cabinet.

3. Remove the vertical frame piece.

4. Disconnect the wire harness connector for the wires that extend to the right side of the circuit breaker.

5. Remove the 12 bolts that connect the connectors for the Circuit Breaker to the three vertical bus bars that are located on the top side of the breaker.

6. Detach the capacitor banks that are located at the bottom of the breaker.

   Refer to Systems Operation, Testing and Adjusting, RENR7654, "Genset Module Circuit Breaker" for removal steps.

7. Disconnect the lower bus bars.

   Each bus bar contains four bolts. There are a total of 12 bolts.

8. Remove the four bolts on the bottom of the breaker that hold the breaker to the lower breaker rail in the cabinet.

   The bolts are located at the bottom two corners of the breaker. Refer to bolt locations in Illustration 1.

9. Ensure that the breaker is supported so that the breaker will not drop during the next step.

10. Remove the four bolts on the top of the breaker that hold the breaker to the upper breaker 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 circuit breaker.

11. Remove the breaker from the cabinet.

    Note the dip switch setting on the front of the breaker.

Installation

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Illustration 2	g01273733

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

2. The breaker is heavy. Fabricate a support for the breaker in preparation for securing the breaker to the cabinet rails.

   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 circuit breaker.

3. Place the new breaker into the cabinet. Support the circuit breaker in place.

4. Attach the breaker to the top breaker rail using four of the eight supplied bolts. Insert the bolts through the front of the top four holes at the back corners of the breaker.

   Refer to Illustration 1.

5. Tighten the top four bolts firmly.

6. Remove the support if it is in the way of installing the bottom bolts.

7. Attach the breaker to the lower breaker rail, use the other four bolts. Insert the bolts through the front of the bottom four holes at the back corners of the breaker.

8. Attach the three lower bus bars. Insert four bolts from the back side through the lower bus and the outputs for the circuit breaker.

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

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

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

10. Attach the capacitor banks, located at the bottom of the breaker.

    Refer to Systems Operation, Testing and Adjusting, RENR7654, "Genset Module Circuit Breaker" for removal steps.

11. Attach the three vertical bus bars to the three inputs at the top of the 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. Attach the right side cable harness connector.

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

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

15. Attach the center vertical frame.

16. Attach the connectors to the Breaker Bell Alarm Supervisor Board that is located at the bottom of the vertical frame piece.