Installation of the Synchronization Module{4480} Caterpillar

Uninterruptible Power Supply:

UPSB 125 (S/N: SEP1-UP)

UPSB 130 (S/N: XTC1-UP)

UPSB 220 (S/N: JFA1-UP)

UPSB 505 (S/N: YTM1-UP)

Introduction

This Special Instruction provides instruction for installing the synchronization module on the listed Uninterruptible Power Supply (UPS) units.

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 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. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use.

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.

Installation

Illustration 1	g02046498
Diagram of single units

Connections

Single Units

Illustration 2	g02131884
Connections for UPSB 125 and UPSB 130 single unit

Illustration 3	g02435977
Connections for UPSB220 single unit

Illustration 4	g02436840
Connections for UPSB 505 single unit

Note: The synchronization module must be grounded at one point only. Refer to Illustration 1.

Refer to the following specifications for cables that exceed 20 m (66 ft):

• Use Two unshielded AWG18 twisted pairs for connection of the D9 connector to the D15 connector.

• Use unshielded 1.5 mm² cable for the remaining connections.

UPS personalization - Set the "External Synchronization Source" parameter to "Yes" with "UPS Tuner" on theUPSB 125, UPSB 130, and the UPSB 505 only. UPSB 220 there is no personalization necessary.

A synchronization board (SYNIN) is installed on the left side of the circuit board rack of each UPS. A 12 m (40 ft) long Sub D9 / Sub D15 cable is supplied with the option.

Illustration 5	g02046878
Detail of cable connections for UPSB 125, UPSB130 and UPSB 505

Illustration 6	g02436938
Detail of cable connections for UPSB 220

If the cable is too short, fabricate a longer cable. Refer to Illustration 5 and Illustration 6. Connect only the four twisted wires that are shown. The maximum length of the fabricated cable is 150 m (492 ft).

Parallel Units

Illustration 7	g02131894
Connections for UPSB 125 and UPSB 130 with three units that are connected in parallel

Illustration 8	g02437099
Connections for UPSB 220 with three units that are connected in parallel

Illustration 9	g02437162
Connections for UPSB 505 with three units that are connected in parallel

Refer to the following specifications for cables that exceed 20 m (66 ft):

• Use Two unshielded AWG18 twisted pairs for connection of the D9 connector to the D15 connector.

• Use unshielded 1.5 mm² cable for the remaining connections.

UPS personalization - Set the "External Synchronization Source" parameter to "Yes" with "UPS Tuner".

A Sub D9 / Sub D15 connection cable is provided for each UPS unit of a parallel UPS system that is equipped with the external synchronization option.

These cables are used for the following purposes:

• Connecting one of the UPS units to the external synchronization module

• Interconnecting the remaining UPS units to each other as shown in Illustration 7

Note: In order to perform maintenance on the UPS, stop the synchronization function by setting the "UNIT STATES" switch to "INHIB RESET". Refer to ""Operation of Display, Rear Panel" ".

Synchronization on External Source

Connections

Illustration 10	g02046886
Connections for an external source

Note: The synchronization module must be grounded at one point only. Refer to Illustration 7.

Refer to the following specifications for cables that exceed 20 m (66 ft):

• Use two unshielded AWG18 twisted pairs for connection of the D9 connector to the D15 connector.

• Use unshielded 1.5 mm² cable for the remaining connections.

The "SOURCES SYNCHRO MODE" switch of the synchronization module must be in "FIXED" mode. The "PREFERRED MASTER" switch is used in order to select the reference source. Refer to ""Operation of Display, Rear Panel" ".

External Synchronization Module

Dimensions and Mounting

Illustration 11	g02046890
Front view and external layout of the synchronization module

Customer Connections

Illustration 12	g02046893
Detail of connections for the synchronization module

The following relay contacts have a 30 W maximum breaking capacity on a resistive load with a 2 A maximum current.

• "UPS1 controlled"

• "UPS2 controlled"

• "Phase in tolerance"

• "Major fault"

Note: The contacts in Illustration 12 are shown in an unactuated state.

Modes of Operation

The synchronization function is used in order to synchronize two or more power sources that are supplying a static transfer switch. There are two possible operating modes for this function.

Automatic source - This mode is used when both sources can be controlled. The "SOURCES SYNCHRO MODE" switch is set to "AUTO".

Fixed source - This mode is used when one source cannot be controlled. This mode is also used when two or more sources must be synchronized with a reference source. The "SOURCES SYNCHRO MODE" switch is set to "FIXED".

Automatic Source Mode

Illustration 13	g02046915
Diagram for two controllable sources

In automatic source mode, the external synchronization function defines the source that will be controlled.

Fixed Source Mode

One Source

Illustration 14	g02046933
Diagram with one controllable source

When only one of the sources can be controlled, the external synchronization function controls that source. This method ensures that the controlling source is synchronized with the source that cannot be controlled.

Multiple Sources

Illustration 15	g02046935
Diagram with two or more sources that are controllable

In order to synchronize two or more controllable sources with the reference source, an external synchronization module is required for each source that is controllable.

Note: The "SOURCES SYNCHRO MODE" switch of each external synchronization module must be set to "FIXED". Refer to ""Operation of Display, Rear Panel" ".

Automatic Source Operation

During normal operation, each UPS synchronizes with the bypass source of the UPS. The external synchronization function remains in sleep mode. The function continues to monitor the two UPS units in order to detect any phase deviation.

When the module detects a phase deviation between the two UPS units that lasts more than 9 seconds, then the following actions occur:

• The synchronization module controls one of the UPS units.

• The UPS that is controlled synchronizes with the UPS that is not controlled.

• A transfer from the inverter to the automatic bypass is disabled for the UPS that is controlled.

After 2 minutes, control is stopped and the synchronization function verifies for 17 seconds that the two units are back in phase. If the units are in phase, then the external synchronization function returns to sleep mode.

If the UPS units are not in phase within 27 seconds, then the synchronization function reverses in order to control the other UPS and the process begins again.

Note: If the synchronization function is unable to control either UPS in order to eliminate the phase deviation, then the function returns to sleep mode.

Common UPS Bypass Sources

Illustration 16	g02046953
Diagram of two UPS units with a common source

A utility or a generator set can be used as a common bypass source for both UPS units in order to supply the static transfer switch.

Bypass Source in Tolerance

A common bypass source is in tolerance under the following conditions:

• The common bypass source is present.

• The frequency is within tolerance.

• The amplitude is within tolerance.

If all of the conditions are true, then both UPS units automatically synchronize with the source. This ensures that the UPS units are synchronized to each other. The synchronization function checks for these conditions. The function remains in sleep mode if the conditions are true.

Bypass Source out of Tolerance

A common bypass source is out of tolerance under any of the following conditions:

• The common bypass source is not present.

• The frequency is not within tolerance.

• The amplitude is not within tolerance.

If any of these conditions are true, then the synchronization module controls one of the units in order to reestablish the synchronization between the units.

Note: The preferred master source is not controlled. This is the reference source that is selected according to the position of the "PREFERRED MASTER" switch. Refer to ""Operation of Display, Rear Panel" ".

Different UPS Bypass Sources

Illustration 17	g02046955
Diagram of two UPS units with different sources

A utility or a generator set can be used as different bypass sources for each individual UPS unit in order to supply the static transfer switch.

Both Bypass Sources in Tolerance

If the synchronization function detects any phase deviation between the UPS outputs, then the function controls one of the UPS units in order to reestablish the synchronization between the units. The unit that is selected as the reference source is determined based on whether the type of the source is available.

Type of source is available - The type can be either a utility or a generator. The UPS that is supplied by the generator will be used as the reference source.

Type of source is not available - The reference source is selected according to the position of the "PREFERRED MASTER" switch. Refer to ""Operation of Display, Rear Panel" ".

One Bypass Source out of Tolerance

When the bypass source of one UPS disappears or goes out of tolerance, then the synchronization function controls that UPS in order to reestablish the synchronization with the other UPS unit.

Both Bypass Sources out of Tolerance

When the bypass sources of both of the UPS units disappear or go out of tolerance, then the synchronization function controls one of the UPS units. This unit acts as a reference source in order to reestablish the synchronization with the other UPS unit.

Note: The preferred master source is not controlled. This is the reference source that is selected according to the position of the "PREFERRED MASTER" switch. Refer to ""Operation of Display, Rear Panel" ".

Fixed Source Operation

Note: Only a single reference source can be used when the "SOURCES SYNCHRO MODE" switch is set to "FIXED". The reference source must be defined by using the "PREFERRED MASTER" switch. Refer to ""Operation of Display, Rear Panel" "

Common Bypass AC Sources

Illustration 18	g02047157
Common bypass AC sources

During normal operation, each UPS synchronizes with the bypass source of the UPS. The external synchronization function remains in sleep mode. The function continues to monitor the sources in order to detect any deviation between the phases of the units.

If a deviation lasting more than 9 seconds occurs between one or more UPS units and the reference source, then the synchronization function immediately controls any UPS that is out-of-phase with the reference source.

A UPS that is controlled will synchronize with the reference source. The controlled UPS is independent with respect to the bypass source that is used for the UPS. The transfer from the inverter to the automatic bypass is disabled for a UPS that is controlled.

Normally, the synchronization function controls the UPS for 2 minutes. After 2 minutes, the control is stopped and a check is performed in order to determine if the UPS can remain in phase with the reference source. If the UPS remains in phase for 17 seconds, then the external synchronization function returns to sleep mode.

If the UPS units are not in phase within 27 seconds, then the synchronization function returns to sleep mode.

Bypass Source in Tolerance

A common bypass source is in tolerance under the following conditions:

• The common bypass source is present.

• The frequency is within tolerance.

• The amplitude is within tolerance.

If all of the conditions are true, then both UPS units automatically synchronize with the source. This ensures that the UPS units are synchronized to each other. The synchronization function checks for these conditions. The function remains in sleep mode if the conditions are true.

Bypass Source out of Tolerance

A common bypass source is out of tolerance under any of the following conditions:

• The common bypass source is not present.

• The frequency is not within tolerance.

• The amplitude is not within tolerance.

If any of these conditions are true, then the synchronization function controls the UPS or any UPS unit that is not defined as the reference source in order to reestablish the synchronization between the units.

Different UPS Bypass Sources

Illustration 19	g02047158

Both Bypass Sources in Tolerance

If the synchronization function detects any phase deviation between the UPS outputs, then the function controls the UPS or any UPS unit that is not defined as the reference source.

Bypass Sources out of Tolerance

When one or more bypass sources disappear or go out of tolerance, then the synchronization function controls the UPS or any UPS unit that is not defined as the reference source.

UPS Display

Illustration 20	g02064534

When a UPS is controlled by the external synchronization module, the alarm light (1) is lighted and a "UPS on external synchronization" message is displayed on the status screen.

Operation of Synchronization Module

Front Panel

Illustration 21	g02064535

The front panel of the synchronization module uses Light Emitting Diodes (LED) in order to display the status of the module. The following indications are present:

"SYNCHRONIZED SOURCE" - The deviation of the phases between the UPS units is within tolerance if this LED is on.

"CONTROLLED SOURCE S1" - Source 1 is the source that is controlled when this LED is on.

"CONTROLLED SOURCE S2" - Source 2 is the source that is controlled when this LED is on.

"MODULE STATUS ACTIVATED" - The synchronization function is activated. There are no minor faults. There are no major faults. The function is not disabled.

"MODULE STATUS INHIBITED" - The synchronization function has been disabled or there is a minor fault or a major fault. Refer to ""Internal Checks" " for faults that could cause this LED to be on.

Rear Panel

Illustration 22	g02064536

The rear panel of the synchronization module contains three switches that are used in order to make selections that are specific to the installation.

"PREFERRED MASTER" - This switch is used in order to select either source 1 "S1" or source 2 "S2" as the source that will be used as the reference source.

"SOURCES SYNCHRO MODE" - This switch is used in order to select the operating mode of the synchronization module. The "FIXED" selection is used in order to specify the fixed source mode. The "AUTO" selection is used is order to specify the automatic source mode.

"UNIT STATES" - This switch is used in order to set the state of the synchronization function. The "INHIB RESET" selection is used in order to disable the synchronization function or in order to reset the synchronization function. The "VALID" selection is used in order to activate the synchronization function.

External Signals

Input Signals

The synchronization function is informed of the type of source by a relay contact. The source can be either a utility or a generator set. The relay contacts determine the source that will be controlled as the reference source. Refer to Table 1.

Output Signals

The following information is indicated by the state of the relay contacts:

"Source 1 controlled" - Two relay contacts are actuated when Source 1 is the source that is controlled.

"Source 2 controlled" - Two relay contacts are actuated when Source 2 is the source that is controlled.

"Sources synchronized" - Two relay contacts are actuated when the phase deviation between the two sources that are being monitored are within tolerance.

"Major fault" - Two relay contacts are actuated when a major fault is detected.

Note: A major fault is an internal fault that results from a failure of the internal clock or the sequencer.

Internal Checks

Minor Fault

Voltage disappears - The synchronization function is disabled. An alarm is issued in order to turn on the "INHIBITED" LED.

Major Fault

An alarm is issued and the "Major Fault" relay is actuated in order to indicate that one of the listed faults has occurred:

Voltage out-of-phase - The "SYNCHRONIZATION SOURCE" LED turns off.

Fault in internal clock - The synchronization function is disabled. The "INHIBITED" LED turns on.

Fault in sequencer - The synchronization function is disabled. The "INHIBITED" LED turns on.

Note: If the synchronization function is disabled, then the module stops controlling all UPS units and the module goes into sleep mode.