PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY RELOCATING POWER CABLES ON CERTAIN 4-WIRE UPS 250, AND UPS 500G UNINTERRUPTIBLE POWER SUPPLIES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY RELOCATING POWER CABLES ON CERTAIN 4-WIRE UPS 250, AND UPS 500G UNINTERRUPTIBLE POWER SUPPLIES

Usage:

TEBE1062-00

Show/hide table

10Mar2014

D-122

O-113

Show/hide table

*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY RELOCATING POWER CABLES ON CERTAIN 4-WIRE UPS 250, AND UPS 500G UNINTERRUPTIBLE POWER SUPPLIES
1408 4459 4480		PI32314

Show/hide table

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32314" 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 "PI32314" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

COMPLETION DATE	TERMINATION DATE
30Sep2014	31Mar2015

PROBLEM

Show/hide table

The existing location of the power cables from CB2 mounted to the output buswork above the K3 contactor can allow the cables to come in contact with the system cabinet frame on certain 4-Wire UPS 250, and UPS 500G Uninterruptible Power Supplies. If the existing location of power cables allows the cables to come in contact with the system cabinet frame, it could cause a short circuit to ground causing damage to the cable and the UPS.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
UPS 500G	TYD00100-00114

PARTS NEEDED

Show/hide table

No parts needed for this program

ACTION REQUIRED

Show/hide table

Inspect the power cables for insulation damage and relocate power cables from bottom mounting point on bus work to next higher mounting point to prevent contact with system cabinet frame.
Refer to the attached Rework Procudure.

Show/hide table

OWNER NOTIFICATION

Show/hide table

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

SERVICE CLAIM ALLOWANCES

Show/hide table

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

Show/hide table

NOTE: This is a 2.0-hour job

Show/hide table

PARTS DISPOSITION

Show/hide table

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

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

Show/hide table

EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY RELOCATING POWER CABLES

MODELS INVOLVED - 4-WIRE UPS 250, AND UPS 500G UNINTERRUPTIBLE POWER SUPPLIES

Dear Cat Product Owner:

The existing location of the power cables from CB2 mounted to the output buswork above the K3 contactor can allow the cables to come in contact with the system cabinet frame on 4-Wire G series UPS. If the existing location of power cables allows the cables to come in contact of the system cabinet frame, it could lead to a short circuit to ground causing damage to the cable and the UPS. 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. Please refer the dealer to their Service Letter dated 10Mar2014 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 10Mar2014 Service Letter

Rework Procedure

Show/hide table

Power cables from CB2 are bolted to the bottom mounting points on the output bus work above the K3 contactor. Location of cables can possibly make contact with frame of system cabinet causing a short to ground. Inspect and relocate power cables from bottom mounting point on bus work to next higher mounting point to prevent contact with system cabinet frame.
Note: UPS must be shutdown prior to commencing work.

Image1.1.1

1. Shutdown UPS in accordance with Systems Operation, Testing and Adjusting, RENR9988.
Inspect assembly cables from CB2 to output bus work. Verify no wear or evidence of arcing on cables.
2. Disconnect assembly cable OUTPUT A/STATIC SWITCH CABLES from middle mounting hole on bus work.
3. Move assembly cable OUTPUT A/STATIC SWITCH CABLES up to top mounting hole on bus work. Torque connection to 45 ft-lbs
4. Repeat Steps 3 & 4 for phases B & C.
5. Disconnect assembly cable CB2/OUT A from bottom mounting hole on bus work.
6. Move assembly cable CB2/OUT A up to middle mounting hole on bus work. Torque connection to 45 ft-lbs
7. Repeat Steps 6 & 7 for phases B & C.
8. Reinspect assembly cables from CB2 to output bus work. Verify cables do not make contact with system cabinet frame.

Image1.2.1

Verifying Relocation Connections:
(UMBC option only) Remove control power fuses (T5 and T6) in I/O Cabinet.
1. Open the Zigzag circuit breaker (CB2).
Trip the bypass breaker (K3) to Open.
2. the control power fuses (T1, T2 and T3) in System Cabinet.
3. Disconnect J1, J11 and J12 on the ACI in the System Cabinet.
4. Open input and output disconnect switches for MMUs in System Cabinet.
5. Isolate UPS from customer load.
6. Perform continuity check on cables. Verify phase (A, B, C) to ground readings are greater than 2 Mohm.
7. Reinstall control power fuses in I/O Cabinet.
8. Reinstall control power fuses in System Cabinet.
9. Close Zigzag circuit breaker (CB2).
10. Reconnect J1, J11 and J12 on the ACI in the System Cabinet.
11. Close input and output disconnects for MMUs in System Cabinet.
12. Restore system to normal operation in accordance with Systems Operation, Testing and Adjusting, RENR9988.