PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE UNDERVOLTAGE COIL ON CERTAIN UPSB125, UPSB130, AND UPSB505 UNINTERRUPTIBLE POWER SUPPLIES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE UNDERVOLTAGE COIL ON CERTAIN UPSB125, UPSB130, AND UPSB505 UNINTERRUPTIBLE POWER SUPPLIES

Usage:

TEBE1353-02

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02Sep2014

(Revised 16Jun2017)

U-511

A-380

D-551

O-432

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE UNDERVOLTAGE COIL ON CERTAIN UPSB125, UPSB130, AND UPSB505 UNINTERRUPTIBLE POWER SUPPLIES
4480		PI10985

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10985" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10985" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 02Sep2014 (Revised 28Oct2014) Service Letter. Changes have been made to the Title, Problem, Parts Needed, and Action Required.

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PROBLEM

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The undervoltage coil on the battery circuit breaker needs to be inspected and possibly replaced on certain UPSB125, UPSB130, and UPSB505 Uninterruptible Power Supplies. The existing undervoltage coil can stick causing the circuit breaker to remain closed and not isolate the batteries and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
UPSB125	SEP00114-00116, 119-127
UPSB130	XTC00114-00140
UPSB505	YTM00100-00124, 126-141

PARTS NEEDED

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Qty	Part Number	Description
1	COIL	UNDERVOLTAGE COIL (See Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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

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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, on the product, and in this product's Operation and Maintenance Manual (OMM). 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, on the product, and in the OMM are not all inclusive. If a tool, procedure, work method, or operating technique not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

The user should ensure that the product will not be damaged and that the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

Action Required

Inspect the DC undervoltage coil for the date code from P11011 through P11537 or from S12011 through S12087.

If the Uninterruptible Power Supply is equipped with a undervoltage coil with a suspect date code, replace the Undervoltage Coil.

Undervoltage Coil Ordering Information

Order a replacement undervoltage coil from one of the contacts shown in Image1. When ordering a replacement coil refer to the information below.

Part Number: American Power Conversion (APC) part number 530-1842.
Part Description: MCCB under-voltage trip, 24V DC MCX100-630.

Refer to the attached Rework Procedure.

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Image1

OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.0-hour job
An additional 2.0 hours is allowed if the coil must be replaced.

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE UNDERVOLTAGE COIL ON CERTAIN UPSB125/130 AND UPSB505 UNINTERRUPTIBLE POWER SUPPLIES

MODELS INVOLVED - UPSB125/130 and UPSB505

Dear Cat Product Owner:

The DC undervoltage coil needs to be inspected and possibly replaced on the products listed below. The existing coil can stick causing the DC breaker to remain closed during a fault and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 02Sep2014 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 02Sep2014 Service Letter

Rework Procedure

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For all UPSB125/130 and UPSB505 Cat Branded UPS, verify the coil date code for each battery
breaker compact NS/NSX 100<=>630. There is one battery breaker per battery cabinet. If multiple battery cabinets are installed there will be multiple battery breakers.
For this check a UPS shutdown on bypass is mandatory
(use the common UPS isolation procedure in the Operation and Maintenance Manual)

Step 1: Trip the Battery Circuit Breaker. Refer to Image 1.2.1

Image1.2.1

Image1.2.2

Step 2: Remove DC Breaker Protective Cover by removing the two mounting screws and check the date code of the undervoltage coil. Replace the coil if the date code is from P11011 to P11537 or from S12011 to S12087. Refer to Image 1.2.2

Image1.3.1

Step 3: Check the date code of the undervoltage coil. Replace the coil if the date code is from P11011 to P11537 or from S12011 to S12087. Refer to Image 1.3.1

Image1.4.1

Step 4: Disconnect the two wires connected to the coil and Remove the coil by pushing up on the breaker lever wile pulling the coil out. The tip of a screwdriver may be used to assist pulling the coil out. Refer to Image 1.4.1

Image1.5.1

5: Install the new coil by pushing up on the breaker lever and pushing the new coil into place. Refer to Image 1.5.1

Image1.6.1

6: Reconnect the two wires to the terminals on the coil and tighten the two connecting screws. Refer to Image 1.6.1

Image1.7.1

7: Install the DC Breaker Protective Cover reusing the existing cover and two mounting screws. Install a new anti tamper sticker supplied with the new coil. Refer to Image 1.7.1.