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

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.

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

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Illustration 1	g01051091

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

   Proceed to Step 6.

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Illustration 2	g00839256

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Illustration 3	g00840027

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

5. 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.

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

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

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

9. Disconnect the ribbon cable and remove ribbon cable from the "Comm/Accel" Board. Remove the "Comm/Accel" Board from the upper bearing cartridge.

10. Remove the 76.20 mm (3/8 inch) stainless steel hex head bolt from the upper bearing cartridge. This bolt secures the castle nut and the spacer to the upper journal of the rotor.

11. Reinstall the 76.20 mm (3/8 inch) stainless steel hex head bolt in the upper journal of the rotor without the castle nut and spacer.

12. Remove all three SAE plugs from the bottom of the flywheel.

13. Remove the vacuum hose and brass fitting from the bottom of flywheel.

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Illustration 4	g00712417

14. Insert all four 190-8366 shims (rotor) into the four bottom SAE ports.

15. Remove all eight 127.00 mm (5/16 inch) stainless steel screws from the bottom bearing cartridge. The rotor will rest on the four 190-8366 shims (rotor) .

    Note: Do not remove the bearing.

16. Install the upper bearing retainer for shipping into the upper bearing cartridge. Tighten the two screws to 13.56 N·m (10.00 lb ft).

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

18. 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.

19. 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.

20. Turn on your Personal Computer.

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Illustration 5	g00840053

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

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Illustration 6	g01003391

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

    The window that is shown in illustration 6 will open.

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

24. 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.

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

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Illustration 7	g01003435

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

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

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

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Illustration 8	g01003470

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

    The window that is shown in illustration 8 will be displayed.

29. Enter "User Name" and "Password".

30. Click on "OK" Button.

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

    The Menu bar will contain a "Calibrate" Option.

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Illustration 9	g01004000

31. Click on "Calibrate".

    The menu that is shown in illustration 9 will appear.

32. 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.

33. Click on "View Status" button.

    Another "Calibration Group Status" window will open.

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

35. 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.

36. 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.

37. Enter the value from step 36 in the "Enter Calibration Point" field.

38. 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.

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

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

41. Click on "OK".

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

42. 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.

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

44. 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.

45. 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.

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Illustration 10	g00697275

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

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

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Illustration 11	g00697276

47. 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.

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Illustration 12	g00697269

48. 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.

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

50. 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.

51. Take this reading from the Gaussmeter.

    Note: A typical value would be 0.256 DC Tesla.

52. Enter the reading from step 51 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.

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Illustration 13	g00697275

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

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Illustration 14	g00697276

54. 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.

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Illustration 15	g00697269

55. 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.

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

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

    Note: A typical value would be 0.026 DC Tesla.

58. 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.

59. 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.

60. 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.

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Illustration 16	g00697275

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

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

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Illustration 17	g00697276

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

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Illustration 18	g00697269

64. 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.

65. Enter the value from step 64 in "Enter Calibration Point" for "Bottom Flux Density 1".

66. 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.

67. 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.

68. 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.

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Illustration 19	g00697275

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

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Illustration 20	g00697276

70. 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.

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Illustration 21	g00697269

71. 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.

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

73. Click on "OK".

74. 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.

75. 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".

76. 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.

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

78. 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".

79. 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.

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

81. 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.

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Illustration 22	g00697275

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

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Illustration 23	g00697276

83. 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.

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Illustration 24	g00697269

84. 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.

85. Enter the value from step 84 in "Enter Calibration Point" for Top Flux Density 1.

    Note: A typical value would be 0.780 DC Tesla.

86. 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".

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Illustration 25	g00697275

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

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Illustration 26	g00697276

88. 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.

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Illustration 27	g00697269

89. 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.

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

91. 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".

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Illustration 28	g00697275

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

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Illustration 29	g00697276

93. 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.

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Illustration 30	g00697269

94. 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.

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

96. 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".

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Illustration 31	g00697275

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

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Illustration 32	g00697276

98. 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.

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Illustration 33	g00697269

99. 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.

100. 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.

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

102. Install the 4 O-ring Plugs.

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

104. 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.

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Illustration 34	g01003513

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

     You will stop receiving the system telemetry.

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

107. Remove the bearing retainer for shipping from the upper bearing cartridge.

108. Remove the 76.20 mm (3/8 inch) stainless steel hex head bolt in the upper journal for the rotor.

109. Install the spacer and the castle nut. Clean the threads of 76.20 mm (3/8 inch)stainless bolts or replace the bolts with new bolts. Place one drop of 7M-7456 bearing mount compound on bolt threads. Install the bolt and torque to 38.00 N·m (28.03 lb ft).

110. Apply 6v-2055 High Vacuum Grease to the O-ring for the "Comm/Accel" board.

111. Install commutation sensor assembly so that the assembly points to the one o'clock and the seven o'clock positions.

     Note: The 12 o'clock position is the center of the back of the cabinet.

112. Install all three screws.

113. Reconnect the ribbon cable for the "Comm/Accel" board.

114. Remove the O-rings from the five removed SAE plugs and grease with 6v-2055 High Vacuum Grease again. Reinstall O-rings to plugs.

115. Reinstall eight screws for the bottom bearing cartridge. Tighten the eight screws. Torque each of the screws to 27.12 N·m (20.00 lb ft).

116. Remove all four shims for the rotor.

117. Apply 6v-2055 High Vacuum Grease to the vacuum hose and reinstall the vacuum hose and the brass fitting into the bottom of the flywheel housing.

118. Reinstall remaining five SAE plugs: Install two of the bolts in the upper half of the flywheel and install three of the bolts in the lower half of the flywheel.

119. Turn on the vacuum pump.

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