Uninterruptible Power Supply (UPS) 250 Caterpillar

Perform this procedure after conducting Testing and Adjusting, "System Controller Board - Remove and Install".

Note: If the procedure Testing and Adjusting, "System Controller Board - Remove and Install" is conducted, the following calibration procedures are required: Testing and Adjusting, "Flywheel Telemetry - Calibrate"Testing and Adjusting, "AC Current - Calibrate", Testing and Adjusting, "AC Voltage - Calibrate" and Testing and Adjusting, "DC Bus Voltage - Calibrate".

Table 1

Required Tools
Part Number	Description
155-5176	AC/DC Current Probe
146-4080	Digital Multimeter
	F.W. Bell Hall Effect Gaussmeter

Rough Calibration

The F.W. Bell Hall Effect Gaussmeter is used in order to conduct these procedures. The Hall Effect Gaussmeter is available from the following distributors:

F.W. Bell
Division of Bell Technologies, Inc.
6120 Hanging Moss Road
Orlando, Florida 32807
www.fwbell.com
Phone: (407) 678-6900Fax: (407) 677-5765

Newark Electronics
(800) 463-9275

Initial Set Up Procedure

1. Place the keyswitch in the BYPASS position.

2. Secure the system. Verify that all the high voltage inputs to the system are open. Ensure that the flywheel is at zero rpm.

3. Remove the sheet metal panels and the lower sheet metal panel for the System I/O Interface Board. The panels are located inside the system.

4. Remove the top baffle plate for the flywheel.

5. Remove the vacuum hose from the top of the vacuum pump in order to release vacuum from the flywheel.

6. Remove the power cord from the rear right hand side of the vacuum pump.

7. Remove the left front 25.4 mm (1 inch) SAE O-ring plug from the top of the flywheel.

8. Remove the right rear 25.4 mm (1 inch) SAE O-ring plug from the top of the flywheel.

9. Remove the left front 25.4 mm (1 inch) SAE O-ring plug from the bottom of the flywheel.

10. Remove the right rear 25.4 mm (1 inch) SAE O-ring plug from the bottom of the flywheel.

Show/hide table



Illustration 1	g00700951
(1) Serial Terminal "J1"

11. Connect a PC to the RS-232/RS-485 port ("J1"). The port is located on the bottom back corner of the system's I/O board. This must be accomplished prior to the application of high voltage to the system.

12. Close the high voltage inputs to the system.

    The system will start. The system will remain in "Bypass". The PC should be communicating with the system.

13. Click on "Enter Password" menu option in order to view the "Enter User Name / Password" dialog box.

Show/hide table



Illustration 2	g00697157
The "Enter User Name / Password" dialog box

14. Enter a valid "User Name" and then enter a valid "Password".

    After the password has been entered, the menu options will change. The menu bar will contain a "Calibrate" option.

Show/hide table



Illustration 3	g00697261
The "Calibrate" pull down menu

15. Click on the "Calibrate" drop-down menu.

16. Select the "Flywheel Telemetry"option.

    This will cause the controller to close the Input Contactor "K1" and Output Contactor "K2". Bypass Contactor "K3" will open.

    In addition, the utility inverter ramps up to ± 450 VDC and the "Calibration of a Channel" window opens.

Show/hide table

Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.

Show/hide table



Illustration 4	g00697264
The "Calibration of a Channel" Window

Show/hide table



Illustration 5	g00697272
The "Calibration Group Status" Window

17. Click on the "View Status" button in the "Calibration of a Channel" window.

    The "Calibration Group Status" window opens. This window displays the status of each channel.

18. Click on "Use Defaults" button. This prompts the system to enter the calibration sequence.

    Note: During the calibration procedure, if the calibration procedure gets out of sequence, start the procedure from the beginning.

19. Proceed to "Top Field Coil Current".

Top Field Coil Current

1. Set the multimeter and set the current probe on "DC Amps".

Show/hide table



Illustration 6	g00697267
The current probe and the field coil driver board (1) Red Lead for the top field coil

2. Connect the current probe around the positive lead of the top field coil on the field coil driver board ("TFC+"). The lead is red. The lead is on the right hand side of the field coil driver board.

3. There is an arrow on the current probe. The arrow points in the direction of the flow of current. Verify that the arrow points away from the board.

4. Adjust the current probe so that the multimeter display is zero.

Show/hide table



Illustration 7	g00697264
The "Calibration of a Channel" Window

5. Select "Top Field Coil Current" from the drop-down menu.

6. Enter a minimum value of "0.000" in the "Enter Calibration Point" field. Then click on the "OK"button.

   Note: Do not enter any values from the multimeter.

   Note: When the "OK" button is depressed, the system will ramp the field coils up to 5 amperes. The status of the "Top Field Coil Current" in the "Calibration Group Status" window will change from "Not Calibrated" to "Minimum value entered". The "MAXIMUM" button will automatically be selected.

7. When the field coil current reaches approximately 5 amperes, read the multimeter display. Record the value that is displayed on the multimeter.

8. Enter the value from Step 7 in the "Enter Calibration Point" field. Then click on the "OK"button. The "Calibration Group Status" window will display "Rough Calibration valid but not saved" for the top field coil current.

9. Proceed to "Bottom Field Coil Current".

Bottom Field Coil Current

1. Verify that the multimeter and the current probe are set on "DC Amps".

Show/hide table



Illustration 8	g00738050
The current probe and the field coil driver board (2) Red Lead for the bottom field coil

2. Connect the current probe around the positive lead of the bottom field coil on the field coil driver board. The lead is red. The lead is on the right hand side of the field coil driver board.

3. There is an arrow on the current probe. The arrow points in the direction of the flow of current. Verify that the arrow points away from the board.

4. Adjust the current probe so that the multimeter display is zero.

Show/hide table



Illustration 9	g00697264
The "Calibration of a Channel" Window

5. Select "Bot. Field Coil Current" from the drop-down menu.

6. Enter a minimum value of "0.000" in the "Enter Calibration Point" field. Then click on the "OK"button.

   Note: Do not enter any values from the multimeter.

   Note: When the "OK" button is depressed, the system will ramp the field coils up to 5 amperes. The status of the "Bot. Field Coil Current" in "Calibration Group Status" window will change from "Not Calibrated" to "Minimum value entered".

   The "MAXIMUM" button will be selected automatically.

7. When the field coil current reaches approximately 5 amperes, read the multimeter display. Record the value that is displayed on the multimeter.

8. Enter the value from Step 7 in the "Enter Calibration Point" field. Then click on the "OK"button. The "Calibration Group Status" window will display "Rough calibration valid but not saved" for the bottom field coil current.

9. Proceed to "Flux Density".

Flux Density

When the rough calibration of the bottom field coil is complete, begin the rough calibration of the hall effect sensors.

The next item in the "Calibration of a Channel" window will be "Top Flux Density 1".

The F.W. Bell Hall Effect Gaussmeter is used in order to calibrate the hall effect sensors.

"Top Flux Density 1"

Show/hide table



Illustration 10	g00697275

1. Insert the probe into the top port on the right hand side. Insert the probe until the tip of the probe touches the rotor.

Show/hide table



Illustration 11	g00697276

2. Continue to insert the probe into the flywheel until the body of the probe is almost all the way inside the port.

Show/hide table



Illustration 12	g00697269
The probe between the pole ring gap and the rotor

3. Rotate the probe slowly. Rotate the probe until the tip of the probe slides in between the pole ring gap and the rotor. Continue to turn the probe until the highest reading is obtained on the meter. Record this measurement.

   Note: Verify that the meter is displaying a positive number. If the number is negative the probe is upside-down.

   Note: Verify that the meter is displaying a value. Verify that the meter is set to measure tesla.

4. Enter "0.". Then enter the value from Step 3. This is the "Minimum Hall Current Reading".

   A typical value would be "0.026".

5. Click the "OK" button.

   When the "OK " button is depressed, the system will apply approximately 5 amperes of field current.

   The "Calibration Group Status" window will display "Minimum value entered" for "Top flux density 1".

6. When the system reaches approximately 5 amperes of field current, observe the meter. Record that value that is displayed on the meter.

7. Enter the value from Step 6 in the "Calibration" window for "Top flux density 1".

   A typical value would be "0.256".

8. Click the "OK" button.

   Note: When the "OK" button is depressed, the status of the "Top Flux Density 1" will change from "Minimum value entered" to "Rough Calibration valid but not saved".

9. Remove the probe from the top right rear port.

10. When the window changes from "Top Flux Density 1" to "TopFlux Density 2", proceed to ""Top Flux Density 2"".

"Top Flux Density 2"

Show/hide table



Illustration 13	g00697275

1. Insert the probe into the top port on the left hand side. Insert the probe until the tip of the probe touches the rotor.

Show/hide table



Illustration 14	g00697276

2. Continue to insert the probe into the flywheel until the body of the probe is almost all the way inside the port.

Show/hide table



Illustration 15	g00697269
The probe between the pole ring gap and the rotor

3. Rotate the probe slowly. Rotate the probe until the tip of the probe slides in between the pole ring gap and the rotor. Continue to turn the probe until the highest reading is obtained on the meter. Record this measurement.

   Note: Verify that the meter is displaying a positive number. If the number is negative the probe is upside-down.

4. Enter "0.". Then enter the value from Step 3. This is the "Minimum Hall Current Reading".

   A typical value would be "0.026".

5. Click the "OK" button.

   When the "OK " button is depressed, the system will apply 5 amperes of field current.

   The "Calibration Group Status" window will display "Minimum value entered" for "Top flux density 2".

6. When the system reaches approximately 5 amperes of field current, observe the meter. Record that value that is displayed on the meter.

7. Enter the value from Step 6 in the "Calibration" window for "Top flux density 2".

   A typical value would be "0.282".

8. Click the "OK" button.

   Note: When the "OK" button is depressed, the status of the "Top Flux Density 2" will change from "Minimum value entered" to "Rough Calibration valid but not saved".

9. Remove the probe from the top left port.

10. When the window changes from "Top Flux Density 2" to "Bottom Flux Density 1", proceed to ""Bottom Flux Density 1"".

"Bottom Flux Density 1"

Show/hide table



Illustration 16	g00697275

1. Insert the probe into the bottom port on the right hand side. Insert the probe until the tip of the probe touches the rotor.

Show/hide table



Illustration 17	g00697276

2. Continue to insert the probe into the flywheel until the body of the probe is almost all the way inside the port.

Show/hide table



Illustration 18	g00697269
The probe between the pole ring gap and the rotor

3. Rotate the probe slowly. Rotate the probe until the tip of the probe slides in between the pole ring gap and the rotor. Continue to turn the probe until the highest reading is obtained on the meter. Record this measurement.

   Note: Verify that the meter is displaying a positive number. If the number is negative the probe is upside-down.

4. Enter "0.". Then enter the value from Step 3. This is the "Minimum Hall Current Reading".

   A typical value would be "0.030".

5. Click the "OK" button.

   When the "OK " button is depressed, the system will apply 5 amperes of field current.

   The "Calibration Group Status" window will display "Minimum value entered" for "Bottom flux density 1".

6. When the system reaches approximately 5 amperes of field current, observe the meter. Record that value that is displayed on the meter.

7. Enter the value from Step 6 in the "Calibration" windowfor "Bottom flux density 1".

   A typical value would be "0.317".

8. Click the "OK" button.

   Note: When the "OK" button is depressed, the status of the "Bottom Flux Density 1" will change from "Minimum value entered" to "Rough Calibration valid but not saved".

9. Remove the probe from the bottom right rear port.

10. When the window changes from "Bottom Flux Density 1" to "Bottom Flux Density 2", proceed to ""Bottom Flux Density 2"".

"Bottom Flux Density 2"

Show/hide table



Illustration 19	g00697275

1. Insert the probe into the bottom port on the left hand side. Insert the probe until the tip of the probe touches the rotor.

Show/hide table



Illustration 20	g00697276

2. Continue to insert the probe into the flywheel until the body of the probe is almost all the way inside the port.

Show/hide table



Illustration 21	g00697269
The probe between the pole ring gap and the rotor

3. Rotate the probe slowly. Rotate the probe until the tip of the probe slides in between the pole ring gap and the rotor. Continue to turn the probe until the highest reading is obtained on the meter. Record this measurement.

   Note: Verify that the meter is displaying a positive number. If the number is negative the probe is upside-down.

4. Enter "0.". Then enter the value from Step 3. This is the "Minimum Hall Current Reading".

   A typical value would be "0.026".

5. Click the "OK" button.

   When the "OK " button is depressed, the system will apply 5 amperes of field current.

   The "Calibration Group Status" window will display "Minimum value entered" for "Bottom flux density 2".

6. When the system reaches approximately 5 amperes of field current, observe the meter. Record that value that is displayed on the meter.

7. Enter the value from Step 6 in the "Calibration" window for "Bottom Flux Density 2".

   A typical value would be "0.310".

8. Click the "OK" button.

   Note: When the "OK" button is depressed, the status of the "Bottom Flux Density 2" will change from "Minimum value entered" to "Rough Calibration valid but not saved".

9. Remove the probe from the bottom left port.

   Note: The values for the "Bottom Flux Density 1" and the "Bottom Flux Density 2" should be close to the same value. If the values are not close to the same value, exit this procedure. Perform this procedure again.

10. When the "Bottom Flux Density 2" window changes to "Final Calibration", proceed to "Fine Calibration".

Fine Calibration

Top Field Coil Current

Note: During the "Fine Calibration" procedure, the field coils will be energized with approximately 15 amperes. The current can cause the temperatures to exceed the alarm setting for the field coils during these procedures. The procedures will need to be restarted after the field coils have cooled.

1. Set the multimeter and set the current probe on "DC Amps".

Show/hide table



Illustration 22	g00697267
The current probe and the field coil driver board (1) Red Lead for the top field coil

2. Connect the current probe around the positive lead of the top field coil on the field coil driver board. The lead is red. The lead is on the right hand side of the field coil driver board.

3. There is an arrow on the current probe. The arrow points in the direction of the flow of current. Verify that the arrow points away from the board.

4. Adjust the current probe so that the multimeter display is zero.

5. When the field coil current reaches 15 amperes, read the multimeter display. Record the value that is displayed on the multimeter.

6. Enter the value from Step 5 in the "Enter Calibration Point" field. Then click on the "OK"button.

   Note: The status of the "Top Field Coil Current" will change from "Rough Calibration valid but not saved" to "Calibration complete but not saved" in the "Calibration Group Status" window.

7. Proceed to "Bottom Field Coil Current".

Bottom Field Coil Current

1. Verify that the multimeter and the current probe are set on "DC Amps".

Show/hide table



Illustration 23	g00738050
The current probe and the field coil driver board (2) Red lead for the bottom field coil

2. Connect the current probe around the positive lead of the bottom field coil on the field coil driver board. The lead is red. The lead is on the right hand side of the field coil driver board.

3. There is an arrow on the current probe. The arrow points in the direction of the flow of current. Verify that the arrow points away from the board.

4. Adjust the current probe so that the multimeter display is zero.

5. Read the multimeter display. Record the value that is displayed on the multimeter.

6. Enter the value from Step 5 in the "Enter Calibration Point" field. Then click on the "OK"button.

   The status of the "Bottom Field Coil Current" will change from "Rough Calibration valid but not saved" to "Calibration complete but not saved" in the "Calibration Group Status" window.

7. Proceed to "Flux Density".

Flux Density

When the fine calibration of the bottom field coil is complete, begin the fine calibration of the hall effect sensors.

The next item in the "Calibration of a Channel" window will be "Top Flux Density 1".

The F.W. Bell Hall Effect Gaussmeter is used in order to calibrate the hall effect sensors.

"Top Flux Density 1"

Show/hide table



Illustration 24	g00697275

1. Insert the probe into the top port on the right hand side. Insert the probe until the tip of the probe touches the rotor.

Show/hide table



Illustration 25	g00697276

2. Continue to insert the probe into the flywheel until the body of the probe is almost all the way inside the port.

Show/hide table



Illustration 26	g00697269
The probe between the pole ring gap and the rotor

3. Rotate the probe slowly. Rotate the probe until the tip of the probe slides in between the pole ring gap and the rotor. Continue to turn the probe until the highest reading is obtained on the meter. Record this measurement.

   Note: Verify that the meter is displaying a positive number. If the number is negative the probe is upside-down. Also, verify that the meter is set to measure tesla.

4. When the system reaches approximately 15 amperes of field current, observe the meter. Record that value that is displayed on the meter.

5. Enter the value from Step 4 in the "Calibration" window.

   A typical value would be 0.759.

6. Click the "OK" button.

   Note: When the "OK" button is depressed, the status of the "Flux Density 1" will change from "Rough Calibration valid but not saved" to "Calibration complete but not saved" in the "Calibration Group Status" window.

7. Remove the probe from the top right rear port.

8. When the window changes from "Top Flux Density 1" to "TopFlux Density 2", proceed to ""Top Flux Density 2"".

"Top Flux Density 2"

Show/hide table



Illustration 27	g00697275

1. Insert the probe into the top port on the left hand side. Insert the probe until the tip of the probe touches the rotor.

Show/hide table



Illustration 28	g00697276

2. Continue to insert the probe into the flywheel until the body of the probe is almost all the way inside the port.

Show/hide table



Illustration 29	g00697269
The probe between the pole ring gap and the rotor

3. Rotate the probe slowly. Rotate the probe until the tip of the probe slides in between the pole ring gap and the rotor. Continue to turn the probe until the highest reading is obtained on the meter. Record this measurement.

   Note: Verify that the meter is displaying a positive number. If the number is negative the probe is upside-down.

4. When the system reaches 15 amperes of field current, observe the meter. Record that value that is displayed on the meter.

5. Enter the value from Step 4 in the "Calibration" window.

   A typical value would be 0.759.

6. Click the "OK" button.

   Note: When the "OK" button is depressed, the status of the "Flux Density 2" will change from "Rough Calibration valid but not saved" to "Calibration complete but not saved" in the "Calibration Group Status" window.

7. Remove the probe from the top left port.

Note: The difference between the value for the "Top Flux Density 1 " and the value for the "Top Flux Density 2" should be less than 0.300. If the difference is greater than 0.300, exit this procedure and perform this procedure again.

8. When the window changes from "Top Flux Density 2" to "Bottom Flux Density 1", proceed to ""Bottom Flux Density 1"".

"Bottom Flux Density 1"

Show/hide table



Illustration 30	g00697275

1. Insert the probe into the bottom port on the right hand side. Insert the probe until the tip of the probe touches the rotor.

Show/hide table



Illustration 31	g00697276

2. Continue to insert the probe into the flywheel until the body of the probe is almost all the way inside the port.

Show/hide table



Illustration 32	g00697269
The probe between the pole ring gap and the rotor

3. Rotate the probe slowly. Rotate the probe until the tip of the probe slides in between the pole ring gap and the rotor. Continue to turn the probe until the highest reading is obtained on the meter. Record this measurement.

   Note: Verify that the meter is displaying a positive number. If the number is negative the probe is upside-down.

4. When the system reaches approximately 15 amperes of field current, observe the meter. Record that value that is displayed on the meter.

5. Enter the value from Step 4 in the "Calibration" window.

   A typical value would be 0.804.

Show/hide table



Illustration 33	g00697272

6. Click the "OK" button.

   Note: When the "OK" button is depressed, the status of the "Bottom Flux Density 1" will change from "Rough Calibration valid but not saved" to "Calibration complete but not saved" in the "Calibration Group Status" window.

7. Remove the probe from the bottom right rear port.

8. When the window changes from "Bottom Flux Density 1" to "Bottom Flux Density 2", proceed to ""Bottom Flux Density 2"".

"Bottom Flux Density 2"

Show/hide table



Illustration 34	g00697275

1. Insert the probe into the bottom port on the left hand side. Insert the probe until the tip of the probe touches the rotor.

Show/hide table



Illustration 35	g00697276

2. Continue to insert the probe into the flywheel until the body of the probe is almost all the way inside the port.

Show/hide table



Illustration 36	g00697269
The probe between the pole ring gap and the rotor

3. Rotate the probe slowly. Rotate the probe until the tip of the probe slides in between the pole ring gap and the rotor. Continue to turn the probe until the highest reading is obtained on the meter. Record this measurement.

   Note: Verify that the meter is displaying a positive number. If the number is negative the probe is upside-down.

4. When the system reaches 15 amperes of field current, observe the meter. Record that value that is displayed on the meter.

5. Enter the value from Step 4 in the "Calibration" window.

6. Click the "OK" button.

   Note: When the "OK" button is depressed, the status of the "Bottom Flux Density 2" will change from "Rough Calibration valid but not saved" to "Calibration complete but not saved" in the "Calibration Group Status" window.

Note: The difference between the value for the "Bottom Flux Density 1 " and the value for the "Bottom Flux Density 2" should be less than 0.300. If the difference is greater than 0.300, exit this procedure and perform this procedure again.

7. Remove the probe from the bottom left port.

8. Click the "SAVE" button.

Show/hide table



Illustration 37	g00738190

9. After the message from illustration 37 is displayed, proceed to "Final Procedure".

Final Procedure

1. Secure the system. Verify that all the high voltage inputs to the system are open. Ensure that the flywheel is at zero rpm.

2. Disconnect the PC from the RS-232/RS-485 port ( "J1"). The port is located on the bottom back corner of the system's I/O board.

Note: Before installing the four 25.4 mm (1 inch) SAE O-ring plugs, Clean the O-rings. Apply a small amount of 6V-2055 Grease to the O-rings.

3. Install the right rear 25.4 mm (1 inch) SAE O-ring plug in the bottom of the flywheel.

4. Install the left front 25.4 mm (1 inch) SAE O-ring plug in the bottom of the flywheel.

5. Install the right rear 25.4 mm (1 inch) SAE O-ring plug in the top of the flywheel.

6. Install the left front 25.4 mm (1 inch) SAE O-ring plug in the top of the flywheel.

7. Connect the power cord to the rear right hand side of the vacuum pump.

8. Install the vacuum hose on the top of the vacuum pump.

9. Install the top baffle plate for the flywheel.

10. Install the upper sheet metal panels and the lower sheet metal panels.