UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies Caterpillar

Note: This procedure should only be performed by service personnel that have been certified by Caterpillar. This procedure should be done after the system has been anchored into position and all wiring has been properly connected.

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NOTICE
The following procedures must be complete before the initial startup of the system: Systems Operation, Testing and Adjusting, RENR2476, "Vibration Sensors Zeroes - Calibrate", Systems Operation, Testing and Adjusting, RENR2476, "Rotor Position Sensor - Adjust" and Systems Operation, Testing and Adjusting, RENR2476, "Rotor Position Sensor - Calibrate"

Starting the System Before the Application of Electrical Power in a Single Module System (SMS)

• Single Module System (SMS) with a Bypass Cabinet

• SMS without a Bypass Cabinet

SMS with a Bypass Cabinet

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Illustration 1	g01796613
User Interface Panel on the Flywheel Cabinet (1) Keyswitch

1. Turn the keyswitch (1) on the Flywheel Cabinet to the "Bypass" position. Refer to Illustration 1.

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Illustration 2	g01797996
Side view of the Bypass Cabinet (10) Bypass Switch (11) Output Switch (12) Input Switch

2. Open the Output Switch (11) that is located in the Bypass Cabinet. Refer to Illustration 2.

3. Open the Input Switch (12) that is located in the Bypass Cabinet. Refer to Illustration 2.

4. Open the Bypass Switch (10) that is located in the Bypass Cabinet. Refer to Illustration 2.

5. Close the Input Switch (12) that is located in the Bypass Cabinet. Refer to Illustration 2.

6. Proceed to "Flywheel Preheat Cycle".

SMS without a Bypass Cabinet

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Illustration 3	g01796613
Flywheel Cabinet User Interface Panel (1) Keyswitch

1. Turn the keyswitch (1) on the Flywheel Cabinet to the "Bypass" position. Refer to Illustration 3.

2. Open the external breaker that powers the input bus of the SMS.

3. Open the external breaker that powers the output bus of the SMS.

4. Close the external breaker that powers the input bus of the SMS.

5. Proceed to "Flywheel Preheat Cycle".

Starting the System Before the Application of Electrical Power in a Multiple Module System (MMS)

• Single Input without Switches

• Single Input with Three Switches

• Dual Input without Switches

• Dual Input with Two Switches

• Dual Input with Three Switches

Single Input without Switches

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Illustration 4	g01796613
User Interface Panel on the System Cabinet (1) Keyswitch

1. Turn the keyswitch (1) on the System Cabinet to the "Bypass" position. Refer to Illustration 4.

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Illustration 5	g01798275
User Interface Panel on the MMU (2) Keyswitch

2. Turn keyswitch (2) on each MMU to the "Bypass" position. Refer to Illustration 5.

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Illustration 6	g01779897
System Cabinet The switches go from MMU 1 to MMU 4 in a descending order. (6) Input Isolation Switches (7) Output Isolation Switches

3. Open the Output Isolation Switches (7) for each MMU that are located in the System Cabinet. Refer to Illustration 6.

4. Open the Input Isolation Switches (6) for each MMU that are located in the System Cabinet. Refer to Illustration 6.

5. Apply facility power to the input node of the system.

6. Proceed to "Flywheel Preheat Cycle".

Single Input with Three Switches

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Illustration 7	g01796613
User Interface Panel on the System Cabinet (1) Keyswitch

1. Turn the keyswitch (1) on the System Cabinet to the "Bypass" position. Refer to Illustration 7.

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Illustration 8	g01798275
User Interface Panel on the MMU (2) Keyswitch

2. Turn keyswitch (2) on each MMU to the "Bypass" position. Refer to Illustration 8.

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Illustration 9	g01802293
Input/Output Cabinet (3) Maintenance Bypass Switch (4) Output Isolation Switch (5) Input Isolation Switch

3. Open the Input Isolation Switch (5) that is located in the Input/Output Cabinet. Refer to Illustration 9.

4. Open the Output Isolation Switch (4) that is located in the Input/Output Cabinet. Refer to Illustration 9.

5. Open the Maintenance Bypass Switch (3) that is located in the Input/Output Cabinet. Refer to Illustration 9.

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Illustration 10	g01779897
System Cabinet The switches go from MMU 1 to MMU 4 in a descending order. (6) Input Isolation Switches (7) Output Isolation Switches

6. Open the Output Isolation Switches (7) for each MMU that are located in the System Cabinet. Refer to Illustration 10.

7. Open the Input Isolation Switches (6) for each MMU that are located in the System Cabinet. Refer to Illustration 10.

8. Close the Input Isolation Switch (5) that is located in the Input/Output Cabinet. Refer to Illustration 9.

9. Proceed to "Flywheel Preheat Cycle".

Dual Input without Switches

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Illustration 11	g01796613
User Interface Panel on the System Cabinet (1) Keyswitch

1. Turn the keyswitch (1) on the System Cabinet to the "Bypass" position. Refer to Illustration 11.

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Illustration 12	g01798275
User Interface Panel on the MMU (2) Keyswitch

2. Turn keyswitch (2) on each MMU to the "Bypass" position. Refer to Illustration 12.

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Illustration 13	g01779897
System Cabinet The switches go from MMU 1 to MMU 2 in a descending order. (6) Input Isolation Switches (7) Output Isolation Switches

3. Open the Output Isolation Switches (7) for each MMU that are located in the System Cabinet. Refer to Illustration 13.

4. Open the Input Isolation Switches (6) for each MMU that are located in the System Cabinet. Refer to Illustration 13.

5. Apply facility power to the input node of the system.

6. Proceed to "Flywheel Preheat Cycle".

Dual Input with Two Switches

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Illustration 14	g01796613
User Interface Panel on the System Cabinet (1) Keyswitch

1. Turn the keyswitch (1) on the System Cabinet to the "Bypass" position. Refer to Illustration 14.

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Illustration 15	g01798275
User Interface Panel on the MMU (2) Keyswitch

2. Turn keyswitch (2) on each MMU to the "Bypass" position. Refer to Illustration 15.

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Illustration 16	g01798373
Input/Output Cabinet (3) Maintenance Bypass Switch (4) Output Isolation Switch

3. Open the Output Isolation Switch (4) that is located in the Input/Output Cabinet. Refer to Illustration 16.

4. Open the Maintenance Bypass Switch (3) that is located in the Input/Output Cabinet. Refer to Illustration 16.

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Illustration 17	g01779897
System Cabinet The switches go from MMU 1 to MMU 4 in a descending order. (6) Input Isolation Switches (7) Output Isolation Switches

5. Open the Input Isolation Switches (6) for each MMU that are located in the System Cabinet. Refer to Illustration 17.

6. Open the Output Isolation Switches (7) for each MMU that are located in the System Cabinet. Refer to Illustration 17.

7. Apply facility power to the input node of the system.

8. Proceed to "Flywheel Preheat Cycle".

Dual Input with Three Switches

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Illustration 18	g01796613
User Interface Panel on the System Cabinet (1) Keyswitch

1. Turn the keyswitch (1) on the System Cabinet to the "Bypass" position. Refer to Illustration 18.

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Illustration 19	g01798275
User Interface Panel on the MMU (2) Keyswitch

2. Turn keyswitch (2) on each MMU to the "Bypass" position. Refer to Illustration 19.

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Illustration 20	g01779896
Input/Output Cabinet (3) Maintenance Bypass Switch (4) Output Isolation Switch (5) Input Isolation Switch

3. Open the Input Isolation Switch (5) that is located in the Input/Output Cabinet. Refer to Illustration 20.

4. Open the Output Isolation Switch (3) that is located in the Input/Output Cabinet. Refer to Illustration 20.

5. Open the Maintenance Bypass Switch (4) that is located in the Input/Output Cabinet. Refer to Illustration 20.

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Illustration 21	g01779897
System Cabinet The switches go from MMU 1 to MMU 4 in a descending order. (6) Input Isolation Switches (7) Output Isolation Switches

6. Open the Output Isolation Switches (7) for each MMU that are located in the System Cabinet. Refer to Illustration 21.

7. Open the Input Isolation Switches (6) for each MMU that are located in the System Cabinet. Refer to Illustration 21.

8. Close the Input Isolation Switch (5) that is located in the Input/Output Cabinet. Refer to Illustration 20.

9. Proceed to "Flywheel Preheat Cycle".

Flywheel Preheat Cycle

Flywheel Preheat Description

The flywheel preheat cycle is a process that attempts to warm the rotor. The system will verify that the flywheel preheat cycle is necessary when the flywheel is started. Different factors are used in order to determine if the flywheel preheat cycle is necessary. The first factor that is used is the flywheel armature temperature.

The flywheel armature temperature is required to be at least 30 °C (86 °F) before the start of the rotation. If the flywheel armature temperature is below 30 °C (86 °F), a flywheel preheat cycle will be automatically initiated. The flywheel preheat cycle is initiated when the following conditions occur:

• The key is turned to the "On-line" position and the flywheel armature temperature is below 30 °C (86 °F).

• The calibration of the rotor position sensor has not occurred yet and the flywheel armature sensor is under 30 °C (86 °F).

If the flywheel armature temperature is greater than 30 °C (86 °F), a flywheel preheat cycle will not normally be performed.

The flywheel armature temperature determines the length of the flywheel preheat cycle. If the flywheel armature temperature is below 30 °C (86 °F), the system will calculate a time for the required flywheel preheat cycle. The length of time for the flywheel preheat cycle is from a minimum of 6 minutes to a maximum of 42 minutes. The preheat is accomplished by sending a 3 phase AC voltage to the flywheel armature at 85 amp.

After the flywheel preheat cycle, a time period for thermal equalization is also determined. This time period is added to the end of the preheat cycle in order to allow the heat in the flywheel armature, that was generated during the flywheel preheat cycle, to radiate to the rotor. The minimum time for equalization is 6 minutes. The maximum time for equalization is 15 minutes. Once the preheat cycle is complete, the system will automatically continue with start-up or the calibration of the rotor position sensor.

Flywheel Preheat Mode

If the power to the flywheel cabinet has been disconnected for more than 48 hours, a 42 minute flywheel preheat cycle will be initiated. In some cases, the full length of time will not be needed. The full length of time can overheat the flywheel armature if the 42 minute process is completed. The overheating of the flywheel armature will result in a delay of obtaining the nominal rotor speed. A password can be used in order to bypass the full length of time for the flywheel preheat cycle. Call your local authorized Cat dealer to gain a temporary non-standard preheat password

The Active Power representative will ask three questions in order to determine if the time of the flywheel preheat cycle can be reduced. You should be prepared to provide the following information:

• The temperature of the room of the flywheel cabinet

• The length of time of the flywheel cabinet existing in the environment

• The length of time for the de-energized flywheel

If the appropriate conditions exist, Active Power will issue a password in order to override the timing for the flywheel preheat cycle. You must have a computer that is connected through a direct serial connection to the module in order to issue the command. Perform a "Ctrl-Shft-6" keystroke in order to enter the password.

Note: Refer to Operation and Maintenance Manual, SEBU7464, "System Startup" in this manual for more information on starting the system.