Uninterruptible Power Supply (UPS) 250 Caterpillar

Initial Set Up Procedure

1. Calibrate the vibration sensors before performing this procedure. Refer to Testing and Adjusting, "Vibration Sensors Zeroes - Calibrate".

   Note: The Calibration procedure for the vibration sensors is only necessary at the initial start-up of the system.

2. Place the keyswitch in the BYPASS position.

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

4. Remove the sheet metal panels and remove the panel for the System I/O Interface Board. The System I/O Interface Board is located in the lower left side of the cabinet.

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

6. Install the temporary power cord between the vacuum pump and a power outlet.

Show/hide table



Illustration 1	g00700951
(1) Serial Terminal "J1"

7. Connect a PC to the RS-232/RS-485 port (1). The port is located on the bottom back corner of the system's SIO board. This must be accomplished prior to the application of high voltage to the system.

8. Verify that the jumper ("J1") on the SIO board is in the proper position. "UP" is for RS485 and "DOWN" is for RS232. The default setting is the DOWN position.

9. Verify that the input voltage is correct.

10. Verify that the phase rotation is correct.

11. 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.

12. 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

13. 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.

14. Depress the "<Ctrl><M>" keys and hold the "<Ctrl><M>" keys.

    The system will enter the "MANUAL" mode.

15. In order to calibrate the commutation sensor, depress the "<Ctrl><C>" keys and hold the "<Ctrl><C>" keys.

    Note: The procedure can also be entered through the "Calibrate" pull-down menu.

16. The system will prompt you to confirm the option. Depress the "<Y>" key. The system will enter the "AUTOMATIC" mode.

    Input Contactor "K1" will close and the static switch is enabled. The bus will ramp to ± 450 VDC.

17. Proceed to "First Phase".

First Phase

The system will close relay CR2 and output contactor "K2". This activates the utility inverter and the field currents increase. The rotor will begin to rotate. During the first phase, 300 RPM is achieved.

During the first phase, the commutation sensor advances from 0° to 255°. This will occur in increments of 3°.

The process takes approximately 5 to 10 minutes.

1. The system shuts down and the system remains in the "MANUAL" mode.

2. Proceed to "Fine Calibration".

Fine Calibration

During the fine calibration procedure, the flywheel slows down and the system ramps over a range of 40 RPM. The system records the time and the system repeats the process. When the process is repeated, the commutation sensor is advanced in increments of 1°. The process repeats over a specified range. The range is 15° above the set point and 15° below the set point. This set point was determined during the "First Phase". The procedure is repeated until the optimal set point for commutation is determined.

The length of the process is approximately 30 minutes. When the procedure is complete, an update of the flash memory will occur. The system will be at 7700 RPM.

1. Place the system in the "Online" mode by moving the key switch to the ON-LINE position.

   The Flywheel conducts a self test and the system ramps to 7640 RPM.

2. After the fine calibration is completed, the system ramps to 7700 RPM. When 7700 RPM is reached, the system enters the standby state.

3. The display will show "Flash Programming Suceeded".

4. Proceed to "Final Procedure".

Final Procedure

1. Disconnect all of the load from the UPS.

Show/hide table



Illustration 3	g00697157
The "Enter User Name / Password" dialog box

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

3. Depress the "<Ctrl><X>" keys and hold the "<Ctrl><X>" keys. This is done in order to bring the system to zero RPM.

   Note: This procedure is only available once during a 24 hour period.

4. Ensure that the flywheel is at zero rpm.

5. Place the keyswitch in the BYPASS position.

6. Open all of the high voltage inputs to the system.

7. Remove the temporary power cord for the vacuum pump.

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

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

10. Install the sheet metal panels for the air ducts.

11. Close the high voltage inputs to the system.

    The current line voltage is displayed and the mode is indicated. the system should be in the "BYPASS" mode.

12. Place the system in the "Online" mode by moving the key switch to the "RESET" position. Then, move the key switch to the "ONLINE" position. The system should start and the flywheel will reach 7700 RPM.

    If a load is applied to the system, the status of the system will change to "Online". This occurs at approximately 4000 RPM.

    Note: If the "NORMAL" status light is flashing, the system is not loaded.