Procedure to Retrofit a Touchscreen on Certain Uninterrupted Power Supply (UPS) Systems. {1418, 4490, 7451} Caterpillar


Procedure to Retrofit a Touchscreen on Certain Uninterrupted Power Supply (UPS) Systems. {1418, 4490, 7451}

Information for equipment:


ELECTRICAL AND STARTING SYSTEM
CONTROL GP-ELECTRONIC

Procedure to Retrofit a Touchscreen on Certain Uninterrupted Power Supply (UPS) Systems. {1418, 4490, 7451} Procedure to Retrofit a Touchscreen on Certain Uninterrupted Power Supply (UPS) Systems. {1418, 4490, 7451}

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Uninterruptible Power Supply
UPS 1000Z (S/N: EDZ103-UP)
UPS 120 (S/N: CNK103-UP)
UPS 1200Z (S/N: HDR115-UP)
UPS 150 (S/N: CPC135-UP)
UPS 250 (S/N: APZ350-UP)
UPS 300 (S/N: CNJ443-UP)
UPS 750 (S/N: AD21-UP; CD71-UP)
UPS500G (S/N: TYD1-UP)
UPS600G (S/N: DLD1-UP)

Introduction

This Special Instruction describes retrofit installation of the Teguar Touchscreen Upgrade Kit for 300 Series and 750 Series Uninterrupted Power Supply (UPS) systems.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Note: The installation requires the disassembly and reassembly of static sensitive devices and the routing and connection of wiring. The retrofit installation is performed in an environment that can contain dangerous voltage levels. Proceed with the retrofit only after reading and understanding the "Important Safety Information" section.

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 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.

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

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.


------ DANGER! ------

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.


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

Power source must be disconnected before working on equipment.

Failure to disconnect power source could result in injury or death.


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

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.


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

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".


General Hazard Information

Note: Always employ accepted industry Lockout / Tagout procedures when-ever performing maintenance requiring the cabinet doors to be opened.

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 1g00104545

Follow the below general hazard instructions:

  • Do not allow unauthorized personnel in or around the system when servicing system.

  • Wear 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 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.

- Repair or replace any equipment that is damaged.

- Remove all tools, electrical cords, unused installation hardware, dirt, debris, and any other loose items before energizing the system.

Fire and Explosion Prevention

Follow the below instructions for fire and explosion prevention:

  • Ensure that the room is ventilated properly.

  • Keep the floor clean of debris.

  • Store oily rags and other flammable material in protective containers.

  • Do not smoke in areas that contain flammable material.

  • Store all lubricants in properly marked containers. Store the protective containers in a safe place.

  • Do not allow flammable materials to accumulate.

  • Wiring must be kept in good condition.

  • Wires must be properly routed and securely attached.

  • Routinely inspect the wiring for wear or for deterioration. Loose wiring, unattached wiring, or unnecessary wiring must be eliminated.

  • All wires and all cables must be of the recommended gauge. Do not use a wire or a cable that is physically smaller than the recommended gauge.

  • The wires and cables must be connected to a fuse or to a circuit breaker, as required. Do not bypass fuses and/or circuit breakers. Arcing or sparking could cause a fire.

The following practices will help prevent arcing and sparking:

  • Use only recommended wiring.

  • Secure all connections.

Grounding Practices

Proper grounding is needed for safety, optimum performance, and reliability. Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.

Uncontrolled electrical circuit paths can cause electrical activity that may degrade the electronics and communications. Ensure that all grounds are secure and free of corrosion.

Proper grounding is required for safe operation of this product.

Electro-Magnetic Compatibility

Federal Communication Commission (FCC) Compliance

This equipment complies with the limits for a Class A digital device and is pursuant to Part 15 of the Federal Communication Commission (FCC) Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates radio frequency energy. This radio frequency energy can radiate from the unit.

If the equipment is not installed and used in accordance with this manual, interference that is harmful to radio communications may occur. Operation of this equipment in a residential area is likely to cause harmful interference. If interference does occur, the user will be required to correct the problem at their own expense.

European Union Compliance

This product has been tested in accordance with EN 50091-2.

Note: This product is a Class A UPS product. In a domestic environment this product may cause radio interference, in which case, the user may be required to take extra measures to reduce conducted (continuous and intermittent) or radiated radio frequency disturbance.

Product Use Policy

Cat UPS products are UL 1778 listed equipment. If you desire to use Cat UPS products in situations that may require listing to another standard, contact your Cat Technical Communicator (TC) to ensure the proper application of products.

Safety Symbols, Labels, and Signs

There may be several specific warning signs on your system. The exact location and a description of the warning signs are reviewed in this section. Become familiar with all warning signs.

Ensure that all the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the Figures are not visible. Use a cloth, water, and soap to clean the warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning signs. The warning signs that are loosened could drop off the system.

Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the system that is replaced, install a new warning sign on the replacement part. Your Caterpillar dealer can provide new warning signs.

Carefully read the text below each safety symbol and label and use professional skills and prudent care when performing the actions described by that text.

Caution/Warning

Read service manual

Risk of Electric Shock

Floating Heat Sink - Test Before Touching

Ground

Wait for 5 minutes after disconnecting all sources of power before the removal of covers or panels.

Telecommunication Connection

No Connection (Telephone) - This symbol is not a connection for a telecommunication network.

No User Serviceable Parts Inside

"ON" Symbol

"OFF" Symbol

Input

Output

Positive Terminal

Negative Terminal

Neutral

DC Current

Alternating Current

Phase

Lithium Battery - There is danger of explosion if the battery is incorrectly replaced. Replace the battery with the same type of battery or replace the battery with an equivalent battery. Dispose of the batteries according to the manufacturer's instructions.

Safety - Extra Low Voltage connections only



Illustration 2g00785184
Bypass Input


Illustration 3g00785185
The system is designed for services that have a three wire grounded wire configuration.


Illustration 4g00785207
The system is designed for services that have a delta configuration.

Instructions for 300 Series Touchscreen Retrofit

Follow the below instructions to replace the existing Weintech touchscreen with the Teguar touchscreen display:



    Illustration 5g06102411
    Teguar display for 300 series
    (1) Display Power Supply PWA
    (2) Top Mounting Bracket
    (3) Display
    (4) Side Mounting Brackets
    (5) New Cable
    (6) Bezel
    (7) Bottom Mounting Bracket

  1. Open the door containing the touchscreen display.

  2. Disconnect and remove existing display cabling from the Display Power Supply PWA (1), the display PWA, and the old display.

  3. Remove the old display.

  4. Remove the old bezel.

  5. Install the new bezel.

  6. Remove Teguar display Side Mounting Bracket (4) and Top Brackets (2).

    Note: The side and top brackets on the new Teguar Display need to be removed, then reinstalled after the display has been carefully installed through the new bezel and existing door openings.

  7. Guide Teguar display into position in new bezel.

  8. Replace Teguar display Side Mounting bracket (4) and Top Brackets (2).

  9. Secure display mounting bracket hardware once the display is in position.

  10. Install new display cabling as shown in Illustration 5.

  11. Check work for continuity and for any loose hardware.

  12. Secure cabinet for operation and return UPS to service.

Instructions for 750 Series Touchscreen Retrofit

Follow the below instructions to replace the existing Weintech touchscreen with the Teguar touchscreen display.



    Illustration 6g06102421
    Teguar display for UPS750 series
    (5) New Cable
    (3) Display
    (6) Bezel
    (8) Customer Input/Output PWA

  1. Open the door containing the touchscreen display.

  2. Disconnect and remove existing display cabling from the Customer Input/Output PWA (8) and the old display.

  3. Remove the old display.

  4. Remove the old bezel.

  5. Install the new bezel.

  6. Remove Teguar display Side Mounting Bracket (4) and Top Brackets (2).

    Note: The side and top brackets on the new Teguar Display need to be removed, then reinstalled after the display has been carefully installed through the new bezel and existing door openings.

  7. Guide Teguar display into position in new bezel.

  8. Replace Teguar display Side Mounting Bracket (4) and Top Brackets (2).

  9. Secure display mounting bracket hardware once the display is in position.

  10. Install new display cabling as shown in Illustration 6.

  11. Check work for continuity and for any loose hardware.

  12. Secure cabinet for operation and return UPS to service.

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