Procedure for Installing Three Phase Flywheel Inverter On Certain Uninterruptible Power Supply{4480} Caterpillar

Uninterruptible Power Supply:

UPS 1000S (S/N: CZS1-UP)

UPS 1000Z (S/N: EDZ1-UP)

UPS 120 (S/N: CNK1-UP)

UPS 1200S (S/N: CZT1-UP)

UPS 1200Z (S/N: HDR1-UP)

UPS 150 (S/N: CPC1-UP)

UPS 250 (S/N: CNM1-UP; APZ1-UP)

UPS 300 (S/N: CNJ1-UP; CPZ1-UP)

UPS 301 (S/N: CSY1-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)

UPS500G (S/N: TYD1-UP)

UPS600G (S/N: DLD1-UP)

Introduction

This Special Instruction outlines the procedure for converting single phase flywheel inverter to three phase flywheel inverter using 449-9066 Converter Module Gp on certain Uninterruptible Power Supply .

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

After power is removed, wait for 5 minutes before the UPS is opened. This action allows the capacitors to discharge. Ensure that the capacitors are at a zero energy level before performing work.

Personal Protective Equipment (PPE) suitable to the work being performed must be worn when performing maintenance on the UPS.

Show/hide table

Working with electrical circuits is hazardous and exposes personnel to electrical potential. To ensure safe operation, personnel must be trained in proper operating procedures. Bodily contact with electrical potential will cause serious personal injury or death.

Show/hide table

High voltage may be present. Work on this equipment must be performed by authorized trained personnel. Failure to disconnect the power source before performing maintenance or removing modules exposes personnel to electrical potential. Bodily contact with electrical potential will cause serious personal injury or death.

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 1	g00104545

Procedure for Installing Three Phase Flywheel Inverter

Perform the following procedure for installing 373-1694 Converter Module Gp (three phase flywheel inverter) using 449-9066 Converter Module Gp :

1. Perform the steps from Systems Operation, RENR9988, "UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies", "Internal Component Preremoval Steps (SMS Bypass Cabinet)" to de-energize the Flywheel cabinet and gain access to internal components.

Note: The Flywheel cabinet must be de-energized before removal steps can be performed.

Show/hide table

High voltage may be present. Work on this equipment must be performed by authorized trained personnel. Failure to disconnect the power source before performing maintenance or removing modules exposes personnel to electrical potential. Bodily contact with electrical potential will cause serious personal injury or death.

2. Remove the Field Coil Driver (FCD) Assembly. Refer to Systems Operation, RENR9988, "UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies", "Field Coil Driver".

3. Disconnect the Ø cable from the right side of the APM/SkiiP Inverter Module.

4. Disconnect +24VDC control power to the Inverter Module, J2 on the MGL Printed Wire Assembly (PWA) or SKI PWA.

5. Remove the ribbon cable from J1 on the MGL PWA or J3 on the SKI PWA.

6. Remove the two mounting bolts from the positive connection of the DC bus.

7. Remove the two mounting bolts from the negative connection of the DC bus.

8. Loosen the two mounting bolts at the top of the heat sink assembly.

Show/hide table

Personal injury or death can result from lifting, moving, and lowering heavy assemblies. A heavy assembly can slip and fall off the forks of the fork lift if the assembly is not properly balanced and secured onto the forks of the fork lift . Be sure that the assembly is properly balanced and secured on the forks of the fork lift. Be sure that the fork lift has the correct capacity to lift the stated weight of the assembly. For reference, the correct weight of the assembly is listed elsewhere within this document information.

Show/hide table

NOTICE
The Flywheel Inverter module is very heavy (32+ lbs). Exercise caution when removing the last bolt so the assembly does not fall and damage components.

9. Slide the module forward and down to remove the old assembly.

10. Remove the remaining inverter modules following the steps above.

11. Disconnect the armature Anderson connector beneath the flywheel assembly and remove the 3Ø armature cables from the right-hand side of the cabinet.

Show/hide table



Illustration 2	g03789442
86250-04, 3Ø cable assembly

12. Route the 86250-04, 3Ø cable assembly.
    Show/hide table
    
    

    Illustration 3	g03789443

    1. Route the cable end with the Anderson Disconnect - to the rear of the cabinet, along the rear cover panel. Pull through enough of the cable to ensure securing cable connector into the mounting location. Refer to Illustration 3.

    2. Route the termination ends of the cable up through the spacing just forward of the Line inductor skins. Refer to Illustration 3.
    Show/hide table
    
    

    Illustration 4	g03789444

    3. Route the cable along the rear corner frame brace and up to the respective phase connection point on the 3-Phase Active Power Module (APM). Refer to Illustration 4.

    4. Use appropriate methods to secure the cabling into position and away from and metal edges that may cut into the cables.

13. Secure the Anderson connector beneath the flywheel.

14. Disconnect the three ribbon cables from APC PWA (J2, J3, and J4) - and remove this inverter ribbon cable assembly.

15. Route the ribbon cable assembly from the APC PWA (J2, J3, and J4) to the flywheel ØB location.

16. Disconnect the +24VDC cables.

    Note: Only one of the +24VDC cables is required to route power to the 3-Phase APM MGL PWA. It is recommended to utilize the longest cable, ØA, to ensure that the cable will reach the new APM Assembly connection point.

    1. Disconnect the J28 (FW SKI/APM ØB) and J29 (FW SKI/APM ØC) on the Power Distribution PWA.

    2. Secure the J28 and J29 cables at the FW SKI/APM side.

17. Locate SKI/APM ØA +24VDC cable, J29 on the PWD PWA to the Flywheel Inverter Module and label with enclosed cable identifier as 85520-97.

18. Install the blanking plates over the ØA and ØC positions of the upper plenum.

19. Slide back 373-1694 Converter Module Gp (8710604-1-S, 3-phase Flywheel APM) into the ØB position on the mounting hardware.

20. Tighten mounting hardware, but do not torque until +/-DC Bus connections are made.

21. Connect the +/-DC Bus to the assembly.

22. Torque +/-DC Bus hardware to 11.29 N·m (100 lb in).

23. Torque upper mounting hardware to 4.52 N·m (40 lb in).

Show/hide table



Illustration 5	g03789445
(1) ØA (2) ØB (3) ØC

24. Connect the ØA, ØB, and ØC leads from the right-hand side of the assembly (ØA is the top connection, with ØB in the middle and ØC on the bottom of the assembly).

25. Torque the ØA, ØB, and ØC hardware to 25 ft/lbs.

26. Connect the 8710739-01, APC ribbon cables, to J1, J2, and J3 on the MGL3 PWA.

27. Connect the 85520-97, +24VDC to J4 on the MGL3 PWA.

28. Install the field coil driver module. Refer to Systems Operation, RENR9988, "UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies", "Field Coil Driver".

Note: It is not necessary to recalibrate the field coils if the field coil driver module has not been replaced.

29. Energize the system according to Testing and Adjusting, RENR9988, "UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies", "System Startup (SMS) - Single Module System", and Testing and Adjusting, RENR9988, "UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies", "System Startup (MMS) - Multiple Module System".