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


Flywheel Telemetry - Calibrate

Usage:

UPS 250 APZ

Calibration Procedure for the Flywheel Telemetry

Note: Perform this procedure whenever the following boards are replaced: Flywheel Interface Board, System Controller Board and Field Coil Driver Board.

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     146-4080     Digital Multimeter     1    
B     155-5176     AC/DC Current Probe     1    
C         F.W. Bell Gaussmeter     1    

  1. Place the key switch in the Bypass position for the MMU that is being calibrated.

    Note: In a Single-Module System, place the key switch in the Bypass position on the System Cabinet.

    Note: Proceed to step 5 for Single-Module Systems.

  1. Connect a PC to the Parallel Cabinet Interface Board that is located in the System Cabinet.



    Illustration 1g01051091

  1. Rotate the switch on the Parallel Cabinet Interface Board to the corresponding Multiple Module Unit.

    Proceed to Step 6.




    Illustration 2g00839256



    Illustration 3g00840027

  1. Remove all sheet metal panels. Remove the sheet metal panel for the System I/O and Isolation Board (2).

  1. Connect a PC to the System RS232/RS485 port that is located on the System I/O and Isolation Board. Make sure that jumper Jmp1 (3) on the System I/O and Isolation Board is in the correct position.

    Note: The lower side is RS232 and the higher side is RS485.

  1. Switch off the vacuum pump. Release vacuum from the Flywheel.

  1. Remove the Top Rear Center O-ring plug from the Flywheel in order to measure Top Flux Density 1.

  1. Remove the Top Front Center O-ring plug from the Flywheel in order to measure Top Flux Density 2.

  1. Remove the Bottom Front Center O-ring plug from the Flywheel in order to measure Bottom Flux Density 1.

  1. Remove the Bottom Rear Center O-ring plug from the Flywheel in order to measure Bottom Flux Density 2.

    Note: Make sure that all personnel are clear before closing the Input Circuit Breaker.

  1. Remove the tags and close the input circuit breaker in order to restore power to the System.

    The System will start, but the system will remain in the Bypass mode.

  1. Turn on your Personal Computer.



    Illustration 4g00840053

  1. Run UPS View by double clicking on the icon (4) on your PC.



    Illustration 5g01003391

  1. Click on "Settings" (7) in the Menu Bar.

    The window that is shown in illustration 5 will open.

  1. Check the "Direct Connect (serial)" radio button (6) .

  1. Select your PC COM Port for this Serial Connection and set the Baud rate.

    The radio button for "Detailed MMU telemetry" (5) must be checked.

  1. Click on "OK" Button (10) in order to accept these settings.



    Illustration 6g01003435

  1. Click on "Connection" on the Menu Bar.

  1. Select "Connect" from the Drop Down Menu.

    You will be connected to the System and you will receive the System Telemetry.




    Illustration 7g01003470

  1. Once you are Connected, Click over the "Enter Password" (13) in the Menu Bar.

    The window that is shown in illustration 7 will be displayed.

  1. Enter "User Name" and "Password".

  1. Click on "OK" Button.

    After the Password has been entered, the Menu Option will Change.

    The Menu bar will contain a "Calibrate" Option.




    Illustration 8g01004000

  1. Click on "Calibrate".

    The menu that is shown in illustration 8 will appear.

  1. Select "Flywheel Telemetry".

    You will hear input contactor "K1" close. The Static Switch will turn on. The DC Bus will rise. A "Calibration of a Channel" window will open.

  1. Click on "View Status" button.

    Another "Calibration Group Status" window will open.

  1. If this window blocks your view of "Calibration of a Channel" window, drag this window aside.

  1. Click on "Use Defaults" that is located on "Calibration of a Channel" window.

    You will be prompted to "Enter Calibration Point" for "Top Field Coil Current".

    Note: The "Minimum" button on "Calibration of a Channel" window is default selection.

  1. Clamp the DC Current probe around the conductor for the positive terminal for the Top Field Coil (TFC) in order to take a reading. Leave the DC current probe that is hanging on this conductor for the next reading.

    This reading should be zero.

  1. Enter the value from step 28 in the "Enter Calibration Point" field.

  1. Click on "OK".

    The System will process the calibration. The system will automatically ramp the current to approximately 5 Amperes. The system will prompt you to "Enter Calibration Point" for "Top Field Coil Current" again.

    Note: "Maximum" Button on "Calibration of a Channel" window will get selected automatically.

  1. Take another reading for the Top Field Coil (TFC).

  1. Enter the value in "Enter Calibration Point" field.

  1. Click on "OK".

    The System will process the calibration. The system will prompt "Enter Calibration Point" for "Bottom Field Coil Current" automatically.

  1. Clamp the DC Current probe around the conductor for the positive terminal for the Bottom Field Coil (BFC). Take a reading.

    This reading should be zero.

    Note: The "Minimum" Button on "Calibration of a Channel" window is the default selection.

  1. Enter this value in "Enter Calibration Point" field.

  1. Click on "OK".

    Leave the DC current probe that is hanging on this conductor for the next reading.

    The System will process the calibration. The system will automatically ramp the current to approximately 5 Amperes. The system will prompt you to "Enter Calibration Point" for "Bottom Field Coil Current" again.

    Note: The "Maximum" Button on "Calibration of a Channel" window gets selected automatically.

  1. Take another reading Bottom Field Coil (BFC) current.

    Leave the DC current probe hanging on this conductor for the next reading.

    The System will process the calibration. The system will prompt you to "Enter Calibration Point" for the Top Flux Density 1 automatically.

    Note: The top field coil current and the bottom field coil current are at zero.




    Illustration 9g00697275

    Note: A Gaussmeter is used in order to calibrate the Flywheel Hall Effect Sensors. The Gaussmeter needs to be set to measure DC Tesla.

  1. Insert the probe to the Gaussmeter into the Top Rear Center port in order to measure Top Flux Density 1.



    Illustration 10g00697276

  1. Insert the probe until the tip of the probe touches the rotor. Continue inserting the probe until the body of the probe is almost all the way inside the port.



    Illustration 11g00697269

  1. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the rotor gap. Continue rotating the probe until you find the highest reading. Leave the probe at this position and make sure that the readings do not change.

    Note: A typical value would be 0.026 DC Tesla.

  1. Enter this value in "Enter Calibration Point" for Top Flux Density 1.

  1. Click on "OK".

    The System will process the calibration. The system automatically ramps the field coil current to approximately 5 Amperes. The readings from the Gaussmeter will change. The readings will become stable when the current reaches the maximum. You will be prompted to "Enter Calibration Point" for Top Flux Density 1.

  1. Take this reading from the Gaussmeter.

    Note: A typical value would be 0.256 DC Tesla.

  1. Enter the reading from step 43 for Top Flux Density 1.

    The System will process the calibration. The system will prompt you to "Enter Calibration Point" for the Top Flux Density 2 automatically.

    Note: The top field coil current and the bottom field coil current are again at zero.




    Illustration 12g00697275

  1. Insert the probe of the Gaussmeter into the Top Front Center port in order to measure Top Flux Density 2.



    Illustration 13g00697276

  1. Insert the probe until the tip of the probe touches the rotor. Continue inserting the probe until the body of the probe is almost all the way inside the port.



    Illustration 14g00697269

  1. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the rotor gap. Continue rotating the probe until you find the highest reading.

  1. Leave the probe at this position. Make sure that the readings do not change.

  1. Enter the value in "Enter Calibration Point" for Top Flux Density 2.

    Note: A typical value would be 0.026 DC Tesla.

  1. Click on "OK".

    The System will process the calibration. The system automatically ramps the field coil current to approximately 5 Amperes. The readings from the Gaussmeter will change. The readings will become stable when the current reaches the maximum points. You will be prompted to "Enter Calibration Point" for Top Flux Density 2.

  1. Take the reading from the Gaussmeter and enter the reading for Top Flux Density 2.

    Note: A typical value would be 0.256 DC Tesla.

  1. Click on "OK".

    The System will process the calibration. The system will prompt you to "Enter Calibration Point" for the "Bottom Flux Density 1" automatically.

    Note: The top field coil current and the bottom field coil current are again at zero.




    Illustration 15g00697275

  1. Insert the probe for the Gaussmeter into the Bottom Front Center port in order to measure Bottom Flux Density 1.

  1. Insert the probe until the tip of the probe touches the rotor.



    Illustration 16g00697276

  1. Continue inserting the probe until the body of the probe is almost all the way inside the port.



    Illustration 17g00697269

  1. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the rotor gap. Continue rotating the probe until you find the highest reading. Leave the probe at this position. Make sure that the readings do not change.

    Note: A typical value would be 0.030 DC Tesla.

  1. Enter the value from step 56 in "Enter Calibration Point" for "Bottom Flux Density 1".

  1. Click on "OK".

    The System will process the calibration. The system automatically ramps the field coil current to approximately 5 Amperes. The readings from the Gaussmeter will change. The readings will become stable when the current reaches the maximum. You will be prompted to "Enter Calibration Point" for Bottom Flux Density 1.

  1. Take the reading from the Gaussmeter and enter the reading for Bottom Flux Density 1.

    Note: A typical value would be 0.310 DC Tesla.

  1. Click on "OK".

    The System will process the calibration. The system will automatically prompt you to "Enter Calibration Point" for the "Bottom Flux Density 2".

    Note: The top field coil current and the bottom field coil current are again at zero.




    Illustration 18g00697275

  1. Insert the probe for the Gaussmeter into the Bottom Rear Center port in order to measure Bottom Flux Density 2.



    Illustration 19g00697276

  1. Insert the probe until the tip of the probe touches the rotor. Continue inserting the probe until the body of the probe is almost all the way inside the port.



    Illustration 20g00697269

  1. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the rotor gap. Continue rotating the probe until you find the highest reading. Leave the probe at this position and make sure that the readings do not change.

    Note: A typical value would be 0.030 DC Tesla.

  1. Enter this value in "Enter Calibration Point" for "Bottom Flux Density 2".

  1. Click on "OK".

  1. The System will process the calibration. The system automatically ramps the field coil current to approximately 5 Amperes. The readings from the Gaussmeter will change. The readings will become stable when the current reaches the maximum. You will be prompted to "Enter Calibration Point" for Bottom Flux Density 2. Take the reading from the Gaussmeter and enter the reading for "Bottom Flux Density 2".

    Note: A typical value would be 0.310 DC Tesla.

  1. Click on "OK".

    The System will process the calibration. The system automatically ramps the field current to approximately 15 Amperes. The system will prompt you to "Enter Calibration Point" for the "Top Field Coil Current".

  1. Clamp the DC Current probe around the conductor for the positive terminal for the Top Field Coil (TFC) and take a reading.

    This reading should be approximately 15 Amperes.

  1. Enter this value in "Enter Calibration Point" field.

  1. Click "OK".

    The System will process the calibration. The system will drop the field coil current to zero. The system automatically ramps the field coil current to 15 Amperes. The system will prompt you to "Enter Calibration Point" for the "Bottom Field Coil Current".

  1. Clamp the DC Current probe around the conductor for the positive terminal for the Bottom Field Coil (BFC) and take a reading.

    This reading should be somewhere near to 15 Amperes.

  1. Enter this value in "Enter Calibration Point" field.

  1. Click "OK".

    The System will process the calibration. The system will drop the field coil current to zero. The system automatically ramps the field coil current to 15 Amperes. The system will prompt you to "Enter Calibration Point" for the Top Flux Density 1.




    Illustration 21g00697275

  1. Insert the probe of the Gaussmeter into the Top Rear Center port in order to measure Top Flux Density 1.



    Illustration 22g00697276

  1. Insert the probe until the tip of the probe touches the rotor. Continue inserting the probe until the body of the probe is almost all the way inside the port.



    Illustration 23g00697269

  1. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the rotor gap. Continue rotating the probe until you find the highest reading.

  1. Enter the value from step 76 in "Enter Calibration Point" for Top Flux Density 1.

    Note: A typical value would be 0.780 DC Tesla.

  1. Click on "OK".

    The System will process the calibration. The system will drop the field coil current to zero. The system automatically ramps the field coil current to 15 Amperes. The system will prompt you to "Enter Calibration Point" for the "Top Flux Density 2".




    Illustration 24g00697275

  1. Insert the probe of the Gaussmeter into the Top Front Center port in order to measure Top Flux Density 2.



    Illustration 25g00697276

  1. Insert the probe until the tip of the probe touches the rotor. Continue inserting the probe until the body of the probe is almost all the way inside the port.



    Illustration 26g00697269

  1. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the rotor gap. Continue rotating the probe until you find the highest reading.

    Note: A typical value would be 0.780 DC Tesla.

  1. Enter this value in "Enter Calibration Point" for "Top Flux Density 2".

  1. Click on "OK".

    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 Tesla. If the difference is greater than 0.300 Tesla exit this procedure, and repeat the Testing and Adjusting, "Flywheel Telemetry - Calibrate" procedure.

    The System will process the calibration. The system will drop the field coil current to zero. The system automatically ramps the field coil current to 15 Amperes. The system will prompt you to "Enter Calibration Point" for the "Bottom Flux Density 1".




    Illustration 27g00697275

  1. Insert the probe of the Gaussmeter into the Bottom Front Center port in order to measure Bottom Flux Density 1.



    Illustration 28g00697276

  1. Insert the probe until the tip of the probe touches the rotor. Continue inserting the probe until the body of the probe is almost all the way inside the port.



    Illustration 29g00697269

  1. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the rotor gap. Continue rotating the probe until you find the highest reading.

    Note: A typical value would be 0.800 DC Tesla.

  1. Enter this value in "Enter Calibration Point" for "Bottom Flux Density 1".

  1. Click on "OK".

    The System will process the calibration. The system will drop the field coil current to zero. The system automatically ramps the field coil current to 15 Amperes. The system will prompt you to "Enter Calibration Point" for the "Bottom Flux Density 2".




    Illustration 30g00697275

  1. Insert the probe of Gaussmeter into the Bottom Rear Center port in order to measure Bottom Flux Density 2.



    Illustration 31g00697276

  1. Insert the probe until the tip of the probe touches the rotor. Continue inserting the probe until the body of the probe is almost all the way inside the port.



    Illustration 32g00697269

  1. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the rotor gap. Continue rotating the probe until you find the highest reading.

  1. Enter this value in "Enter Calibration Point" for "Bottom Flux Density 2" and Click on "OK".

    Note: A typical value would be 0.800 DC Tesla.

    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 Tesla exit this procedure, and repeat the Testing and Adjusting, "Flywheel Telemetry - Calibrate" procedure.

  1. Clean the O-rings. Apply a small amount of 6V-2055 Grease to the O-rings.

  1. Install the 4 O-ring Plugs.

  1. Close the release valve for the flywheel vacuum. Start the vacuum pump.

  1. Click on "Save" on "Calibration of a channel" window.

    You will hear the Input Contactor "K1" open.

    The Calibration ends. You will see the message "Flash reprogrammed OK" on the text window of UPS View. This indicates that the Calibration has been successfully completed.




    Illustration 33g01003513

  1. To disable the connection in UPS View, click "Connection" on the menu bar, and select "Disconnect".

    You will stop receiving the system telemetry.

  1. Unplug the RS232 cable from the System I/O and Isolation Board.

  1. Return the sheet metal to the cabinets. Close the doors for proper air flow into the system.

Caterpillar Information System:

3044C Industrial Engine and Engines for Caterpillar Built Machines Engine Oil Bypass Valve - Remove and Install
G3500 Engines MID 018 - CID 0552 - FMI 11 Engine Speed present during an O2 calibration
G3500 Engines MID 018 - CID 0551 - FMI 01 Oxygen Sensor not connected to buffer
2003/06/01 Improved Radiator for the Generator Set Engine {1353}
G3520C and G3520E Generator Set Engines Piston and Connecting Rods - Install
G3520C and G3520E Generator Set Engines Piston and Connecting Rods - Remove
G3304 and G3306 Engines Crankshaft - Install
3500 Engines Fuel Filter Housing - Install
3500 Engines Fuel Filter Housing - Remove
G3304 and G3306 Engines Crankshaft - Remove
3406C Marine Auxiliary Generator Set Plate Locations and Film Locations
G3304 and G3306 Engines Camshaft Bearings - Install
G3520C and G3520E Generator Set Engines Cylinder Liner - Install
3508C, 3512C and 3516C Marine Engines Camshaft Bearings - Remove
Replacing the Convection Jacket Water Heaters with a Recirculating Jacket Water Heater on 3500 Engines{1383} Replacing the Convection Jacket Water Heaters with a Recirculating Jacket Water Heater on 3500 Engines{1383}
3508C, 3512C and 3516C Marine Engines Camshaft Bearings - Install
C3.3 Industrial Engine Engine - Clean
2003/07/01 An Improved Spin-On Oil Filter Is Now Available {1306, 1308}
Installation of the 249-2439 Seal {1371} Installation of the 249-2439 Seal {1371}
C7 Engines for Combat and Tactical Vehicles Cruise Control Parameters
C7 Engines for Combat and Tactical Vehicles Smart Idle Parameters
C7 Engines for Combat and Tactical Vehicles Timer Parameters
UPS 250, UPS 300, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supply Vibration Sensors Zeroes - Calibrate
3406C Marine Auxiliary Generator Set Safety Messages
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.