- Uninterruptible Power Supply:
- UPS 120 (S/N: CNK1-UP)
- UPS 1000S (S/N: CZS1-UP)
- UPS 1200S (S/N: CZT1-UP)
- UPS 150 (S/N: CPC1-UP)
- UPS 250 (S/N: BEE1-UP; CNM1-UP; APZ1-UP)
- UPS 300 (S/N: CNJ1-UP; CPZ1-UP)
- UPS 500 (S/N: CSE1-UP)
- UPS 600 (S/N: CTX1-UP)
- UPS 750 (S/N: CPM1-UP)
- UPS 900 (S/N: CRY1-UP)
- UPS 1000S (S/N: CZS1-UP)
Introduction
This Special Instruction will describe the proper procedure in order to replace the "System Input/Output " (SIO) and the "Daughter System Input/Output" SIOD boards. The "Universal Network Interface" (UNI) "Printed Wire Assembly" (PWA) will replaced the SIO and the SIOD boards.
The following information applies to "Multi Module Systems" (MMS) that are used for the Uninterruptible Power Supply (UPS) systems.
Do not perform any procedure that is outlined in this special instruction, or order any parts until the entire special instruction has been read and understood.
Important Safety Information
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.
You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.
Required Part
| Required Part | ||
|---|---|---|
| Qty | Active Power Part Number | Description |
| Varies with Application | 609-0392 | PWA |
System Characteristics
All of the new UPS systems use UNI PWA. The UNI PWA have built-in terminators.
The UNI PWA replaces the SIO board and the SIOD board in a Multi Module Unit (MMU).
The single PWA, input relays, and output relays are not needed in the multiple module units. The system cabinets and the "Single Module Systems" (SMS) still use the SIO and the SIOD boards. The single module systems only use SIODs with certain options.
The boards that are to be changed will only occur in the MMU cabinets of the MMS. The stand-alone SMS and the system cabinets of the MMS will continue to utilize the SIO PWA and the SIOD PWA. The SIO and the SIOD PWA are needed for the input and output contacts. The input and output contacts are not incorporated on the UNI PWA.
The terminating resistors are activated by the use of jumpers that are on the UNI PWA. The jumpers allow the selection of desired terminating resistors in order to provide the termination. Therefore, plug in terminating resistors are not required for the MMU at the end of the "UPS Net" communication chain.
"Controlled Area Network" (CAN) is now enabled by positioning jumpers on the UNI PWA.
Note: Some of the connector designations may appear to be redundant, for example J4 and J4'. The apostrophe annotates a connection to a secondary part of the UNI PWA, which replaces the old SIOD. Another example can be seen in the illustration that shows J8 and J8'. J8 is the systems "UPS Net Primary" communication port. J8' is the systems "UPS Net Backup" communication port.
The UNI PWA is interchangeable with all of the existing SIO and SIOD PWA.
The UNI PWA provides an isolation barrier between the controller and all of the communications ports that are used by the cabinet.
Communications for the MMS
All communications to the UNI and MMU cabinets are routed to the system cabinet. The following list shows the internal connections.
- Ethernet
- RS-232/RS-485
- Modem
- Primary UPS Net
- Backup UPS Net
- CAN
The UNI PWA has a selectable communication port. The selection can be set to either RS-232 or RS-485. The method of selection is accomplished via the "JMP1" port that is located on the UNI PWA.
| JMP1 | |
|---|---|
| Pins | Sets Port As |
| 1 and 2 | RS-485 |
| 2 and 3 | RS-232 (default) |
Since the UNI PWA contains onboard terminating resistors, plug in terminating resistors are not required for the MMU at the end of the "UPS Net" communication chain. The onboard jumpers allow the resistors to be enabled or disabled in order to provide the termination. "JMP2", "JMP3", and "JMP4" must all be enabled or all must be disabled.
| Port | Function |
|---|---|
| JMP 2 | "UPS Net Primary" |
| JMP 3 | "CAN" |
| JMP 4 | "UPS Net Backup" |
| JMP2 | |
|---|---|
| Pins | Termination |
| 1 and 2 | Enabled |
| 2 and 3 | Disabled |
| JMP3 | |
|---|---|
| Pins | Termination |
| 1 and 2 | Enabled |
| 2 and 3 | Disabled |
| JMP4 | |
|---|---|
| Pins | Termination |
| 1 and 2 | Enabled |
| 2 and 3 | Disabled |
Remote Emergency Power Off
The UNI PWA contains a connection point for "Remote Emergency Power Off" (REPO).
The UNI PWA has the capability to work with a "Normally Open" REPO system or a "Normally Closed" REPO system. If no REPO is connected in the system or if the "Normally Open" circuit is used, then a jumper must be installed on the "Normally Closed" circuit.
 | |
| Illustration 1 | g01923554 |
(1) UNI PWA | |
System Shut Down
 |
High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures. |
 |
|
Personal injury or death can result from high voltage. Moisture can create paths of electrical conductivity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls "DO NOT OPERATE". |
|
Always practice "Electrostatic Discharge" (ESD) prevention when handling printed wire assemblies.
Perform the following steps in order to shut down the UPS in order to access to the internal components.
General Hazard Information
Attach a "Do Not Operate" warning tag or a similar warning tag to the key switch or to the controls before the system is serviced or before the system is repaired. These warning tags are available from your Caterpillar dealer. Attach the warning tags to the system and to each operator control station.
 | |
| Illustration 2 | g00104545 |
- Do not allow unauthorized personnel on the system, or around the system when the system is being serviced.
- Wear a hard hat, protective glasses, and other protective equipment, as required.
- Do not wear loose clothing or jewelry that can snag on controls or on other parts of the system.
- Report all necessary repairs.
Unless other instructions are provided, perform the maintenance under the following conditions:
- The system is stopped and the system is disconnected from power. Ensure that the system cannot be powered or ensure that power cannot be applied to the system.
- Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.
- Remove all tools, electrical cords, and any other loose items from the system before starting the system.
Board Replacement
Board Removal
- Refer to the "System Shut Down" procedure before attempting to replace any of the boards.
- Disconnect the connectors. The connectors are labeled in order to match the locations in the unit. Verify that each connector is appropriately labeled before being removed. Refer to Illustration 3.
- Unscrew the phillips head ground screw from the J11 connection point that is located at the top of the UNI PWA.
 | |
| Illustration 3 | g01923556 |
(4) JMP Locations | |
- Use the following method in order to disconnect the white plastic stand-offs that mount the UNI PWA to the left panel.
Note: The UNI PWA must be removed from the stand-offs without bending it.
- Pinch the head of each stand-off so that the UNI PWA is not locked but is still attached to the stand-off.
- Remove the UNI PWA gently. Evenly pull the UNI PWA from all of the stand-offs at the same time.
Installation
Always practice "Electrostatic Discharge" (ESD) prevention when handling printed wire assemblies.
- Position the board over the white stand-offs that are connected to the left panel.
- Push the board gently and evenly onto all the stand-offs simultaneously. Ensure that all of the stand-offs are locked into place on the board.
- Insert the phillips head ground screw in the board that was removed from the J11 connection point. Tighten the screw.
- Plug the wire connectors into the correct connectors on the board. Check the labels on each connector for proper placement. Refer to Illustration 3.
- Ensure that the correct fuses are installed for the UNI PWA. Refer to Table 7.
Show/hide table
Table 7 Fuse Type F1 Littelfuse 2173.15 250VAC 3.15A Fast F2 Littelfuse 217002 250VAC 2A Fast F3 Littelfuse 217002 250VAC 2A Fast F4 Littelfuse 217002 250VAC 2A Fast F5 Littelfuse 217002 250VAC 2A Fast F6 Littelfuse 2173.15 250VAC 3.15A Fast F7 Littelfuse 217002 250VAC 2A Fast