PRODUCT SUPPORT PROGRAM FOR UPGRADING THE DIGIT AND GDET FIRMWARE ON CERTAIN UPSB505 DOUBLE CONVERSION UNINTERRUPTIBLE POWER SUPPLIES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPGRADING THE DIGIT AND GDET FIRMWARE ON CERTAIN UPSB505 DOUBLE CONVERSION UNINTERRUPTIBLE POWER SUPPLIES

Usage:

TEBE0039-00

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30Jul2013

D-287

O-285

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPGRADING THE DIGIT AND GDET FIRMWARE ON CERTAIN UPSB505 DOUBLE CONVERSION UNINTERRUPTIBLE POWER SUPPLIES
4480		PS43971

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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 "PS43971" 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

31Jul2015

PROBLEM

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The existing DIGIT and GDET Firmware has several faults on certain UPSB505 Double Conversion Uninterruptible Power Supplies. If the existing firmware is not upgraded it can cause the following: 1. Incoherence between UPS time in parallel installation, 2. PFC current regulation fault not reset automatically, 3. PFC FAN no detected in maintenance mode, 4. Detection of "chopper divergent current fault" after starting charging, 5. Battery wear ratio not functioning, 6. Dry contact "general alarm" and HMI red led not activated with internal CAN bus fault.

AFFECTED PRODUCT

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Model	Identification Number
UPSB505	YTM00100-00124, 126-134

PARTS NEEDED

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Qty	Part Number	Description
1	FILE1	34020880-AQ
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

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Upgrade the DIGIT and GDET Firmware. Refer to the attached Rework Procedure. Firmware 34020880-AQ is available in SIS Web. Refer to SIS/Downloads/Double Conversion UPS Software.

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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%
0-90000 hrs, 0-120 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 0.5-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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Objective:
Firmware upgrades to DIGIT and GDET boards on the UPSB505.

New feature:
- 440V inverter output voltage
- New UPS tuner command to test Battery breaker coil trip

Fault corrections:
- See Appendix for list of Fault Corrections

Functionality improvements:
- Output capacitor fault could be detected on specific load. A new personalization parameter was added titled "Inverter output capacitor control" to disable the control.
- Software improvements on "Internal CAN communication fault"

Resolution task:
- New firmware AQ is developed to correct and implant the above items.
o Hardware PCBA DIGIT (365-9798) to NT11 Index EQ pre loaded
o Hardware PCBA GDET (365-9799) to NT12 Index CJ pre loaded
- UPS Tuner to be upgraded to 3.4.1.11 version
- Network Management Card firmware must be 5.1.3 revision or higher

Instructions:
Before going on site, install and register UPS Tuner to 3.4.1.11 version from PowerNet (https://engines.cat.com/ep/products/ups/conversion/tuner)

Also, download the package index AQ from SISweb under the Downloads section under Double Conversion UPS Software.

Firmware AQ is not compatible with firmware < or = AN in parallel installations. (Integrated parallel or parallel with SSC) The Technician must schedule a transfer on Manual Bypass (Q3BP) for firmware upgrade < or = AN.

Firmware AQ is compatible with firmware AP in parallel installations. (Integrated parallel or parallel with SSC) The Technician must upgrade each unit one by one (other UPS stay on line)

NOTE: Compatible means that the installation must be upgraded at same visit.
=> It is not allowable to run more than one day with AP&AQ firmware

Upgrade for parallel with SSC. The Technician may upgrade each unit one by one (other UPS stay on line) then Open Q4S to upgrade SSC firmware (UPS stay on line) and Close Q4S after upgrade. Confirm this operation with the user as a system without a bypass (Q4S Open) could drop the load if there is fault during the upload.

Once on site, update the firmware at commissioning or during the next scheduled visit by following instructions in REHS7351.

NOTE: AQ firmware can be downloaded on all DIGIT and GDET boards.

Verify the Network Management Card has firmware 5.1.3 or higher.

NOTE: Network Management Card firmware can be found on SIS under the Downloads section. Instructions for installation of firmware can be found on REHS7450

Appendix - Fault corrections
1. Incoherence between UPS time in parallel installation: - In some cases, UPS time in parallel installation is incoherent.
- This behavior has been corrected.

2. PFC current regulation fault not reset automatically (appeared after 6 attempts of PFC restart):
- Now PFC current regulation fault is reset automatically after a temporization.

3. PFC FAN no detected in maintenance mode:
- This behavior has been corrected.

4. Detection of "chopper divergent current fault" after starting charging:
- This behavior has been corrected.

5. Battery wear ratio not functioning:
- This behavior has been corrected.

6. Dry contact "general alarm" and HMI red led not activated with internal CAN bus fault:
- This behavior has been corrected.