- Uninterruptible Power Supply:
- UPSB 125 (S/N: SEP1-UP)
- UPSB 130 (S/N: XTC1-UP)
- UPSB1100 (S/N: PHL1-UP)
- UPSB220 (S/N: JFA1-UP)
- UPSB500 (S/N: JFN1-UP)
- UPSB505 (S/N: YTM1-UP)
- UPSB 130 (S/N: XTC1-UP)
Introduction
This Special Instruction provides information that is related to the styles of connectors and the usage of those connectors for the listed devices.
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 specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.
You should ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
Use tools and torque recommendations that are provided by the manufacturer of the connector. Refer to the latest catalog of the manufacturer and to the instructions that are provided with the connector when the connector is installed.
General Information
The information that is shown in this manual is only for reference. Any connector may be used if the connector is certified in the country of use for your application. Some standards of certification include the following:
- Underwriters Laboratory (UL)
- Canadian Standards Association (CSA)
- International Standards Organization (ISO)
- Autrailian Standards/New Zealand Standards (AS/NZS)
Use the tools and use the torque values that are recommended by the manufacturer of the connector.
Types of Connectors
Connectors will be one of the following types:
- Mechanical
- Compression
A mechanical connector is reusable. The connector will be made of copper or aluminum. The aluminum connectors are rated for use with both copper and aluminum. Each connector can be used with several different wire sizes.
Typically, a compression connector is permanent. This style of lug connectors is crimped to the conductor. The connector is made for a specific wire size. The connector can be easily installed. The connector can be readily inspected for a proper crimp and a proper connection.
Both of these types of connectors may be available with a single hole or with two holes. The connectors with two holes are ideal for bolting to bus bars because the use of two bolts prevents the connector from turning.
General Considerations
The following factors should be considered when connectors are used:
- Never use copper connectors on wires that are made of aluminum.
- The wire size that is used with the connector is generally stamped on the body of the connector. A larger connector may be required for connectors that contain fine strands of wire.
- When conductors are terminated, the metal surfaces that contact the conductors should be coated with a joint compound in order to prevent the surface of the connector from oxidizing.
Note: Ensure that you are selecting the correct joint compound for your application. Some joint compounds are used in order to bind aluminum to aluminum. Other joint compounds are used in order to bind aluminum to copper.
Connectors
Mechanical Connectors
 | |
| Illustration 1 | g02070277 |
Typical mechanical connectors | |
Illustration 1 shows a few types of mechanical connectors that are available for use.
- The connector is used on conductors with aluminum or copper wire that is stranded.
- The connector may contain an inspection window in order to ensure that the conductor is inserted fully.
- The connector can contain one hole or two holes for the bolts that secure the connector.
- The barrel of the connector is sized in order to accommodate different sizes of wires.
- The connector can contain multiple barrels in order to attach more than one wire.
Dimensions
 | |
| Illustration 2 | g02070279 |
Dimensions of a typical mechanical connector (A) Radius of bolt hole (B) Center of bolt hole to front of connector (C) Depth of tongue (D) Width of connector (E) Length of connector | |
Refer to Illustration 2 in order to specify a connector for your application. These dimensions are typically used by manufacturers in order to select a connector for a specific use.
Note: The dimensions of connectors can typically vary between +/- 0.03 inches.
Compression Connectors
 | |
| Illustration 3 | g02070935 |
Typical compression connectors (1) Splice connector | |
- The connector is a compression style lug.
- The connector may be filled with joint compound at the factory.
- The barrel is sized in order to accommodate a specific wire size.
- The barrel may contain a plug that is removable in order to specify the wire size.
- The barrel may be marked with the wire size or the barrel may have a colored sleeve in order to specify the wire size.
- The end of the barrel may contain knurl bands. These bands indicate the number of crimps and the placement of the crimps.
- Lugs with blank tongues are available for special sizes of bolt holes or for special applications.
- Some of the lugs are manufactured with a barrel that is bent to a 45 degree angle or to a 90 degree angle.
The splice connector (1) that is shown in Illustration 3 is a special type of compression connector that is used on flexible cable with fine strands. The splice is crimped over the conductor and then inserted into the terminal lug of a circuit breaker. A splice connector is also used in order to join two conductors.
Dimensions
 | |
| Illustration 4 | g02070793 |
Dimensions of a typical compression connector (2) Plug that is found on some connectors (A) Radius of bolt hole (B) Center of bolt hole to front of connector (C) Depth of tongue (D) Width of connector (E) Length of connector | |
Note: If the lug contains two holes for bolts, the lug can be ordered with a distance that is specified between the centers of the holes.
 | |
| Illustration 5 | g02071595 |
Dimensions of a typical splice connector (F) Inside diameter of connector (G) Length of connector (H) Outside diameter of connector | |
Refer to Illustration 4 and Illustration 5 in order to specify a connector for your application. These dimensions are typically used by manufacturers in order to determine a connector for a specific use.
Note: The dimensions of connectors can typically vary between +/- 0.03 inches.
Installation Instructions for Connectors
Mounting a Connector
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| Illustration 6 | g02074036 |
Mounting detail for connections (3) Bus bar or other connection point (4) Flat washer (5) Bolt (6) Part or parts (7) Flat washer (8) Compression device (9) Nut | |
Refer to the following in order to create a mechanical connection that is electrically sound.
The head of the bolt (5) and the nut (9) must be constructed of either stainless steel or of medium carbon steel that has been quenched and tempered. Fastening devices that are made of stainless steel have a characteristic shine.
 | |
| Illustration 7 | g02074099 |
Typical grade markings of bolts | |
The grade of carbon steel for these fastening devices is indicated by marks on the nut or the bolt. For example, a Society of Automotive Engineers (SAE) Grade 5 bolt will have three lines that are equally distributed on the head of the bolt. An American Society for Testing and Materials (ASTM) Type 1 bolt will have an additional marking of "A325" between the lines.
Note: Do not use the fastening device if you are not sure of the properties of the material of the device. Charts are available for determining the grade of the carbon steel.
If the part or parts (6) that are being connected are made of soft metal, then install a flat washer (4) between the head of the bolt and the parts. Examples of soft metals are aluminum, copper, lead, and tin. Install a second flat washer (7) between the compression device (8) and the bus bar or other connection point (3).
If the holes in the part are much larger than the bolt, then both flat washers are still required. This is true even if the part is made of hard metal such as steel or iron.
 | |
| Illustration 8 | g02074102 |
Orientation of a belleville washer (8) Compression device (9) Nut | |
Use the correct compression device and install the device correctly. The compression device (8) must be contacting the nut (9). The compression device can be a split washer or a belleville washer. A split washer will put most of the pressure at the split. Use belleville washers when an even distribution of pressure around the connection is required. Orient a belleville washer so that the convex end is facing the driving force.
Note: If more than one belleville washer is used, all belleville washers must be oriented in the same direction.
Always hold the head of the bolt in place and turn only the nut in order to tighten the connection. Ensure that the length of the bolt allows at least three threads to extend past the end of the nut after the connection is tightened.
 | |
| Illustration 9 | g02075753 |
Typical star washers | |
Never use a star washer as a compression device on a high power electrical connection. Ground straps that are used for safety may have a star washer because the connector does not carry current. The washer is used for digging through the paint in order to make contact with the metal surface. Ground straps that use star washers should never be stacked.
 | |
| Illustration 10 | g02074113 |
Orientation of bolt (9) Nut | |
On batteries that are constructed per Illustration 10, ensure that the nut (9) that is used for connecting the cable to the post points away from the battery. This orientation allows adequate clearance for the socket of a torque wrench.
Note: The length of screws and bolts shall provide a minimum of 1 1/2 threads and a maximum that is limited by the nearest practical standard length of the screw beyond the nut or joining surfaces, except when such projections would invalidate good workmanship or when the projections would invalidate the requirements of the design.
Connecting a Conductor to a Mechanical Connection
Use the following procedure in order to connect a conductor to a mechanical connector.
- Remove the insulation that is around the conductor of the wire.
Ensure that you do not nick the strands of the conductor or do not damage the strands.
- Carefully remove the oxide film on the outer strands of the conductor.
Lightly brush the strands with a wire brush or use fine sandpaper in order to remove the film.
- Apply a joint compound to the conductor in order to prevent oxidation.
- Insert the cable into the barrel of the connector (11) .
 | |
| Illustration 11 | g02073641 |
Typical mechanical connector (10) Set screw (11) Connector (12) Conductor | |
- Tighten the set screw (10) against the conductor (12) .
Table 1 contains the typical torque that is required in order to tighten the set screw.
Note: Refer to the specifications that are provided by the manufacturer of the connector in order to determine the torque that is required.
Show/hide tableTable 1 Tightening Torque for Set Screws Size of Threads in Inches
Torque lb-in n-m 1/4 72 8.2 5/16 132 15.0 3/8 228 25.8 7/16 360 40.8 1/2 540 61.2 5/8 1116 126.5
Connecting a Conductor to a Compression Connection
Use the following procedure in order to connect a conductor to an aluminum compression lug.
- Select the proper connector.
Use a connector that is marked for the wire size that will be used.
Note: Never use a copper connector on aluminum wire.
- Remove the insulation that is around the conductor of the wire.
Ensure that you do not nick the strands of the conductor or damage the strands.
- Carefully remove the oxide film on the outer strands of the cable.
Lightly brush the strands with a wire brush or use fine sandpaper in order to remove the film.
- Apply a joint compound to the conductor in order to prevent oxidation.
Note: Some lugs are manufactured with joint compound in the barrel of the lug.
- Insert the conductor (12) into the connector 11.
 | |
| Illustration 12 | g02073974 |
Typical compression connection (11) Connector (12) Conductor | |
- Insert the connector into the die.
Ensure that you select the correct installation tool and select the correct die for the wire that will be crimped.
- Crimp the connector onto the wire.
Note: The connector may contain knurl marks in order to indicate the correct location for crimping.
- Inspect the connection for the following: sharp edges, flash, burns and excess joint compound.
Using a Splice Connector
The following procedure provides instruction for connecting a splice connector to a conductor for use in a breaker box.
- Select the proper connector.
Use a connector that is suitable for the wire size that will be used.
Note: Never use a copper connector on aluminum wire.
- Remove the insulation that is around the conductor of the wire.
Ensure that you do not nick the strands of the conductor or damage the strands.
- Carefully remove the oxide film on the outer strands of the cable.
Lightly brush the strands with a wire brush or use fine sandpaper in order to remove the film.
- Insert the conductor into the splice connector.
- Crimp the splice connector (14) to the conductor.
Ensure that you select the correct installation tool for the wire that is being crimped.
 | |
| Illustration 13 | g02073995 |
Installed Splice connector in a circuit breaker (13) Set screw (14) Splice connector (15) Lug | |
- Insert the splice connector into the lug (15) of the circuit breaker.
- Tighten the set screw (13) against the splice connector.
Table 2 contains the typical torque that is required in order to tighten the set screw.
Note: Refer to the specifications that are provided by the manufacturer of the connector in order to determine the torque that is required.
Show/hide tableTable 2 Tightening Torque for Set Screws Socket Size Across Flats Tightening Torque Inches Millimeters lb-in n-m 1/8 3.2 45 5.1 6/32 4.0 100 11.3 3/16 4.8 120 13.6 7/32 5.6 150 16.9 1/4 6.4 200 22.6 5/16 7.9 275 31.1 3/8 9.5 375 42.4 1/2 12.7 500 56.5 9/16 14.3 600 67.8