PRODUCT SUPPORT PROGRAM FOR REPLACING THE SPRING-CAGE TYPE TERMINAL BLOCKS IN THE POWER DISTRIBUTION PANEL ON CERTAIN PM3512C HD, AND PM3516C HD POWER MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE SPRING-CAGE TYPE TERMINAL BLOCKS IN THE POWER DISTRIBUTION PANEL ON CERTAIN PM3512C HD, AND PM3516C HD POWER MODULES

Usage:

TEBE4495-00

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20May2016

U-262

A-202

D-234

O-229

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE SPRING-CAGE TYPE TERMINAL BLOCKS IN THE POWER DISTRIBUTION PANEL ON CERTAIN PM3512C HD, AND PM3516C HD POWER MODULES
4460 7426		PS45082

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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 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 "PS45082" 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.

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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.

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TERMINATION DATE

31May2018

PROBLEM

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The existing spring-cage type terminal block does not meet 100kAIC rating on certain PM3512C HD, and PM3516C HD Power Modules.

AFFECTED PRODUCT

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Model	Identification Number
PM3512C HD	N1G00100-00102, 117-118, 120
PM3516C HD	N1M00102-00116, 118-220, 222-280, 283, 287, 292, 294

PARTS NEEDED

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Qty	Part Number	Description
7	5080534	BLOCK-TERMINAL
1	5080552	COVER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is 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 or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
WARNING: The generator set must be isolated 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.

Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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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%
0-10000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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TERMINAL BLOCK REPLACEMENT
The following steps detail the field replacement of seven terminal blocks on the terminal strip located in the lower right corner of the VFD section of the power module panel.

STEP 1: De-Energize The Panel.
Lock-Out and Tag-Out the main Masterpact circuit breaker (located on left side of double door panel) and any other Auxiliary Power sources connected to the panel. Use a suitable voltage measurement device to confirm that both the Line and Load side bus work of the Masterpact circuit breaker are de-energized.

STEP 2: DC Bus Voltage:
The panel contains a Variable Frequency Drive (VFD). Wait minimum of 15 minutes for the VFD DC bus capacitors to discharge. Then follow the DC Bus Voltage Measurement Procedure to verify the DC voltage is less than 42 V. The VFD LEDs are not indicators of the absence of DC bus voltage.

STEP 3: DC Bus Voltage Measurement Procedure:
Determine the DC bus voltage level by monitoring the PA/+ and PC/- terminals.
IMAGE 1.4.1 shows the position of the PA/+ and PC/- terminals underneath the VFD's front access cover.

Image1.4.1

To measure the DC bus capacitor voltage:
1. Observe the lock-out/tag-out procedures.
2. Wait fifteen minutes for the DC bus capacitors to discharge.
3. Remove the front cover of the VFD to access the PA/+ and PC/- terminals.
IMAGE 1.5.1 shows the VFD front with the front cover and with the front cover removed.
4. Set the voltmeter to the 1000 Vdc scale. Measure the voltage between the PA/+ and PC/- terminals.
5. Verify that the DC bus voltage has discharged below 42 V before servicing the VFD. If the DC bus capacitors will not discharge below 42V, contact your local Schneider Electric representative. Do not operate the drive.
6. After verifying the DC bus voltage is below 42V, reinstall the front access cover.

Image1.5.1

STEP 4: Terminal Block Replacement:
The following seven terminal blocks (IMAGE 1.6.1) will need to be replaced, F521, F522, F523, E857A, E858A, PR1, and PR2 (IMAGE 1.6.2).

Image1.6.1

Image1.6.2

4A. Loosen the securement screw of the top DIN rail end-anchor block with a flat head screw driver and remove it or slide it vertically upwards as far as possible.

4B. Slide the terminal blocks F521 - PR2 upwards about a 1/4 to 1/2 inch (6 - 13 mm). Replace each terminal block one at a time to minimize miss-wiring. The conductor wire identification is printed onto the conductor's insulation. Refer to IMAGE 1.8.1 and IMAGE 1.8.2 for conductor wire identification and terminal wiring diagram.

Image1.8.1

Image1.8.2

4C. Start with the PR2 terminal block first (seventh one from the top, refer to IMAGE 1.9.1).
Remove the wiring from the terminal block. Terminal blocks have spring cage clamp type terminals. Refer to IMAGE 1.9.2 for illustration on how to remove the wiring from the terminal block using a small flat headed screw driver.
Insert screw driver into respective terminal clamp lever opening. To open terminal clamp, push down on the screw driver and pull the screw driver in the opposite direction of wire terminal. This will cause the tip of the screw driver to open the spring clamp mechanism allowing the conductor to be removed from the terminal block. Repeat this process for all the terminals of this 3 pole terminal block. Then remove the terminal block from the DIN rail.

Image1.9.1

Image1.9.2

4D. Replacement screw-type terminal blocks will have the same terminal marker identification as the old terminal blocks. Select the replacement terminal block with the same designation as the one just removed and install it onto the DIN rail. Keep the same orientation as previously removed terminal block, single terminal on the left side and double terminal on the right side, refer to IMAGE 1.10.1. Insert the previously removed wiring into the new terminal block and tighten terminal screws to 0.8 N-m (7 in-lbs).

Image1.10.1

4E. Slide terminal block downward firmly against the one below it. Repeat steps 4C ? 4E for each of the remaining terminal blocks needing to be replaced.

4F. Once all seven (7) terminal blocks have been replaced. Recheck the wiring to each terminal block against IMAGE 1.12.1 and IMAGE 1.12.2. Reinstall the top DIN-rail end anchor block and tighten its securement screw.

Image1.12.1

Image1.12.2

4G. IMAGE 1.13.1 shows completed terminal block replacement.

Image1.13.1

STEP 5: Start Up And Test:
Before energizing equipment:
? Replace any covers removed during the terminal block replacement.
? Remove tools, meters, and debris from the equipment.
? Close and secure the enclosure doors.
? Remove any Lock-Out Tag-Out devices applied.
? Perform all start-up tests recommended by the equipment manufacturer.