PRODUCT SUPPORT PROGRAM FOR UPDATING THE FIRMWARE TO VERSIONS 5.41/5.42 ON CERTAIN UPS 1000Z, UPS 1200Z, UPS 1000, UPS 1200, UPS 150, UPS 250, UPS 300, UPS 301 UPS 500, UPS 600, UPS 750, AND UPS 900 UNINTERRUPTIBLE POWER SUPPLIES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE FIRMWARE TO VERSIONS 5.41/5.42 ON CERTAIN UPS 1000Z, UPS 1200Z, UPS 1000, UPS 1200, UPS 150, UPS 250, UPS 300, UPS 301 UPS 500, UPS 600, UPS 750, AND UPS 900 UNINTERRUPTIBLE POWER SUPPLIES

Usage:

REBE9984-02

Show/hide table

03Jul2013

(Revised 21Nov2013)

U-293

A-201

D-250

O-249

Show/hide table

*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE FIRMWARE TO VERSIONS 5.41/5.42 ON CERTAIN UPS 1000Z, UPS 1200Z, UPS 1000, UPS 1200, UPS 150, UPS 250, UPS 300, UPS 301 UPS 500, UPS 600, UPS 750, AND UPS 900 UNINTERRUPTIBLE POWER SUPPLIES
7620 4480		PS43951

Show/hide table

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43951" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

Show/hide table


NOTE:	This Revised Service Letter replaces the 03Jul2013 (Revised 11Jul2013) Service Letter. Changes have been made to the Affected Product and Action Required.

Show/hide table

TERMINATION DATE

31Jul2015

PROBLEM

Show/hide table

On UPS firmware versions prior to 5.41/5.42, the output under voltage fault detection was too sensitive to voltage disturbances. Firmware versions prior to 5.41/5.42 can on entry into discharge due to some forms of input disturbances cause the UPS to go to bypass which could potentially drop the load.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
1000IZ UP	EDZ00100-00111, 113-119
1200Z UPS	HDR00100-00146, 150-153
UPS 150	CPC00135-00138, 150
UPS 250	APZ00342-00349, 351-358, 360-364 CNM00242
UPS 300	CNJ00438-00477 CPZ00373-00378
UPS 500	CSE00157-00162
UPS 500G	TYD00100-00105, 114
UPS 600	CTX00335-00352
UPS 600G	DLD00100-00101, 104-111
UPS 750	CPM00172
UPS 900	CRY00406-00412

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	FILE1	UPS SMS APC1+ v5.41
1	FILE2	UPS MMS APC1+ v5.42
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 23% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

Show/hide table

Note: This program applies only for UPS units equipped with APC1+ boards. UPS units equipped with APC1 boards and running 3.xx/3.60/3.61 do not apply and must not perform this program.

Update the UPS Firmware to version 5.41 for Single Module Systems and to 5.42 for Multi Module Systems.
Firmware is available in SIS / Downloads / Flashfiles / UPS SMS APC1+ v5.41 or UPS MMS APC1+ v5.42.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-90000 hrs, 0-120 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 1.0-hour job

Show/hide table

PARTS DISPOSITION

Show/hide table

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Show/hide table

These versions of firmware can be used in 300 Series (E, iC, D, G, & Z Series) MMS and PMMS products with APC1Ps. This code cannot be loaded in the old APCs. This code must be updated with UPSView 2.8.5 or newer.

Obtain an event log (ctrl+d) before the firmware update as this update may erase the event log.

The entire UPS (MMS or PMMS) must be in maintenance bypass prior to beginning the firmware update. The entire UPS should also be free of Alarms and Notices prior to beginning the firmware update.

The firmware update should be performed by loading all of the files into all of the PWAs (SCCs and APC1+s) and then cycle power to the entire UPS. Do not reboot APC1Ps or SCCs until all of the files have been loaded.

When the firmware is loaded, the NEW parameters should be checked to insure that their default values are loaded. Performing an alt+z (report non-default Op. Params.) before and after the firmware update will make it easy to view the new parameters.

Image1.1.1

Select target to be programmed: This pull-down menu is used to select the target (PWA) to be programmed. The only valid choices are: PowerPC Application, APC1 FPGA Firmware, and SCC FPGA Firmware.

Browse for target file to be used: Displays the file and its location on your PC that will be loaded into the target.

Download firmware progress: Displays the progress bar as the file is being loaded into the target.

The Program Button is used to begin the file transfer to the target. This button should only be pushed when the target and target file are correct.

The Exit Button is used close the firmware update dialog box. (after all files have been updated)

The Advanced Button is NOT used to update firmware. None of the check boxes under this menu should be checked.

The Browse Button is used to select the target file.

The Reload Device Button should NOT used to update firmware. It is required to reboot all devices after they have the new firmware installed. This should be done be cycling power to the UPS while the UPS is in maintenance bypass.

The Read Back Button is NOT used to update firmware.

Manual Files (MMS)
The entire UPS (MMS or PMMS) must be in maintenance bypass during the firmware update.

Updating the firmware involves transferring a minimum of 3 files via UPSView to the UPS. There is 1 file for the SCC PWA in the system cabinet and 2 files for each APC1P PWA in each MMU. The SCC file should be loaded first.

Procedure (MMS)

1. Confirm that the UPS is in maintenance bypass
2. Connect a personal computer to the UPS RS232 port in the system cabinet with via UPSView 2.8.5
3. Select MMU #1 with the PCI rotary switch in the system cabinet.
4. Click on Enter Password and enter a valid user name and password.
5. On the computer, enter Alt+z and record the operating parameters other than defaults for a later comparison.
6. On the computer, enter Ctrl+d. which will download the log file from the UPS memory.
7. Click on the UPS Settings Menu, select Update UPS Firmware.
8. In the Firmware Update Dialog box, click on the down arrow on the right-hand side of the pull-down menu. Select "SCC FPGA Firmware".
9. In the Firmware Update Dialog box, click on the Browse Button.
10. Select the correct target file to be inserted into the SCC FPGA (SCC_FPGA_5_40.ttf) and click open.
11. Click on the Program Button.
12. You should see an increase in the progress bar, indicating the firmware is going into the target.
13. When the text to the left of the progress bar indicates the firmware update is complete with no errors it is safe to continue. This may take about 5 minutes.
14. In the text window of UPSView, confirm that the following message exists: mm/dd/yyyy hh:mm:ss.ms Code Update: successful [device 3, size #######] If this message is not received go back to step 11.
15. In the Firmware Update Dialog box, click on the down arrow on the right-hand side of the pull-down menu. Select "PowerPC Application".

Image1.4.1

16. In the Firmware Update Dialog box, click on the Browse Button.
17. Select the correct target file to be inserted into the PowerPC Application (mms_apc1p_prod_app_5_42.mot) and click open.
18. Click on the Program Button.
19. You should see an increase in the progress bar, indicating the firmware is going into the target.
20. When the text to the left of the progress bar indicates the firmware update is complete with no errors it is safe to continue. This may take about 2 minutes.
21. In the text window of UPSView, confirm that the following message exists: mm/dd/yyyy hh:mm:ss.ms Code Update: successful [device 1, size #######]
22. In the Firmware Update Dialog box, click on the down arrow on the right-hand side of the pull-down menu. Select "APC1 FPGA Firmware".
23. In the Firmware Update Dialog box, click on the Browse Button.
24. Select the correct target file to be inserted into the APC1 FPGA (sms_mms_apc1p_fpga_5_40.ttf) and click open.
25. Click on the Program Button.
26. You should see an increase in the progress bar, indicating the firmware is going into the target.
27. When the text to the left of the progress bar indicates the firmware update is complete with no errors it is safe to continue. This may take about 3 minutes.
28. In the text window of UPSView, confirm that the following message exists: mm/dd/yyyy hh:mm:ss.ms Code Update: successful [device 2, size #######]
29. In the Firmware Update Dialog box, click exit.
30. Select the next MMU with the PCI rotary switch in the system cabinet.
31. Click on the UPS Settings Menu, select Update UPS Firmware.
32. Go back to Step 15 and continue until all MMUs have been updated. It is not necessary to perform the update to the SCC after it has been completed on MMU1.
33. For an MMS, after all MMUs have been updated, the Update Firmware Procedure is complete.
34. For a Parallel MMS, go back to Step 2 and repeat the procedure for the other MMSs.
35. After all SCCs and MMUs have been updated confirm that there is a "Code Update: successful [device *, size #######]" message for every SCC and 2 "Code Update: successful [device *, size #######]" messages for every APC1.
36. Cycle power to the entire UPS and confirm that the correct firmware is in every SCC and APC1 using ctrl+n.
37. Go to the Parameters section on Page 6 of this document.

Manual Files (SMS)
The UPS must be in maintenance bypass during the firmware update.

Updating the firmware in an SMS involves transferring 2 files via UPSView to the UPS. These 2 files are for the APC1P PWA in each MMU.

Image1.6.1

Procedure (SMS)

1. Confirm that the UPS is in maintenance bypass
2. Connect a personal computer to the UPS RS232 port in the MMU with via UPSView 2.8.5
3. Click on Enter Password and enter a valid user name and password.
4. On the computer, enter Alt+z, and record the operating parameters other than defaults for a later comparison.
5. On the computer, enter Ctrl+d. which will download the log file from the UPS memory.
6. Click on the UPS Settings Menu, select Update UPS Firmware.
7. In the Firmware Update Dialog box, click on the down arrow on the right-hand side of the pull-down menu. Select "PowerPC Application".
8. In the Firmware Update Dialog box, click on the Browse Button.
9. Select the correct target file to be inserted into the PowerPC Application (mms_apc1p_prod_app_5_41.mot) and click open.
10. Click on the Program Button.
11. You should see an increase in the progress bar, indicating the firmware is going into the target.
12. When the text to the left of the progress bar indicates the firmware update is complete with no errors it is safe to continue. This may take about 2 minutes.
13. In the text window of CSView, confirm that the following message exists: mm/dd/yyyy hh:mm:ss.ms Code Update: successful [device 1, size #######]
14. In the Firmware Update Dialog box, click on the down arrow on the right-hand side of the pull-down menu. Select "APC1 FPGA Firmware"
15. In the Firmware Update Dialog box, click on the Browse Button.
16. Select the correct target file to be inserted into the APC1 FPGA (sms_mms_apc1p_fpga_5_40.ttf) and click open.
17. Click on the Program Button.
18. You should see an increase in the progress bar, indicating the firmware is going into the target.

19. When the text to the left of the progress bar indicates the firmware update is complete with no errors it is safe to continue. This may take about 3 minutes.
20. In the text window of UPSView, confirm that the following message exists: mm/dd/yyyy hh:mm:ss.ms Code Update: successful [device 2, size #######]
21. After the 2 files have been updated confirm that there are 2 "Code Update: successful [device 1/2, size #######]" messages.
22. Cycle power to the UPS and confirm that the correct firmware is in the APC1 using ctrl+n.
23. Go to the Parameters section on Page 6 of this document.

Parameters (SMS and MMS)

It is possible that there are new parameters that have been introduced with the new firmware.

1. On the computer, enter Alt+z, and compare this list to the Alt+z that was obtained prior to update (step 5 for MMS, step 4 for SMS).
2. Click on the Enter Password and enter a valid user name and password.
3. Find the new parameters in the Op. Params. menu and set them to their default value.
4. On the computer, enter Alt+z, and confirm that there are no more parameters that need to be programmed.

"Capt Falling Edge Trigs" It has been determined that 65 is a better setting for this parameter. Set to 65 which is not default.

It is possible that a few of the new parameters are not shown in the Operating Parameters Menu, because they require a different password. In this case, these parameters can be set to default with the "Load restricted default Params to Flash"command. This command is in group 4 of the Commands menu. If this command is to be used it must be used on every MMU.

The firmware update is complete.