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

Calibration Procedure for the AC Current

Note: This procedure needs to be accomplished with the use of a load bank. Do not use the facility load for this calibration.

Note: Perform this procedure whenever the following components are replaced: AC Interface Board and System Controller Board. Calibration of the AC Voltage is also required.

1. Bring the RPM of the system to zero.

2. 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 6 for Single-Module Systems.

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

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Illustration 1	g01051091

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

   Proceed to Step 7.

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Illustration 2	g00839256

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Illustration 3	g00840027

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

6. 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.

7. Close the Input Circuit Breaker in order to restore power to the System.

   The System will start but the key will remain in "Bypass".

8. Start your PC.

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Illustration 4	g00840053

9. Run UPS View by double clicking over the icon (7) on your PC.

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Illustration 5	g01003391

10. Click on the "PC Settings" (7) in the menu bar.

    The "UPS View Connection Settings" window that is shown in illustration 5 will open.

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

12. Select your PC COM port (8) for this serial connection and set the baud rate (9) .

    Note: The radio button for "Detailed MMU Telemetry" must be checked.

13. Click on "OK" Button in order to accept these settings.

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Illustration 6	g01003435

14. Click on "Connection" on the menu bar.

15. 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 7	g00840122

16. Once you are connected, click over the "Enter Password" (13) in the menu bar.

    The "Enter User Name/Password" window that is shown in illustration 7 will appear.

17. Enter "User Name" and "Password".

18. Click on "OK" button.

    After the password has been entered, the menu option will change.

    The menu bar will contain a "Calibrate" option.

    Note: Make sure that the flywheel vacuum is less than 58 mTorr before the system starts this calibration.

19. Click on "Calibrate".

20. Select "AC Currents".

    You will hear input contactor K1 and output contactor K2 close. The static switch will turn on. The DC Bus voltage will increase. A "Calibration of a Channel" window will open.

21. Click on "View Status" button.

    Another "Calibration Group Status" window will open.

22. Drag the "Calibration Group Status" window aside if the view of "Calibration of a Channel" window is blocked.

23. Click on "Use Defaults" on "Calibration of a Channel" window.

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Illustration 8	g00840916

Note: Add the approximate full load to the system while the system remains in the bypass mode.

Note: Make sure that the Bypass Isolation Switch is open.

24. You will be prompted to "Enter Calibration Point" for "Current in Phase A".

    Also note that "Maximum" Button on "Calibration of a Channel" window is the default selection.

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Illustration 9	g00840945

25. Clamp the AC current probe around the input conductor for "Phase A" in order to take a reading.

26. Enter the value from step 25 in the "Enter Calibration Point" field.

27. Click "OK".

    The system will process the calibration and the system will prompt you to "Enter Calibration Point for Current in Phase. B" automatically. The "Calibration Group Status" window will display "Calbration Complete but not saved for the current in Phase. A". Refer to illustration 9.

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Illustration 10	g00841034

28. Clamp the AC current probe around the input conductor for "Phase B" in order to take a reading.

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

30. Click on "OK".

    The system will process calibration and the system will prompt you to "Enter Calibration Point for Current In Phase C" automatically. The "Calibration Group Status" window will display "Calbration Complete but not saved for the current in Phase. B".

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Illustration 11	g00841047

31. Clamp the AC current probe around the input conductor for "Phase C" in order to take a reading.

32. Enter the value from step 31 in the "Enter Calibration Point" field.

33. Click on "OK".

    The System will process Calibration and the system will prompt you to "Enter Calibration Point for Current out Phase A" automatically. The "Calibration Group Status" window will display "Calibration Complete but not saved for the current in Phase. C".

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Illustration 12	g00841119

34. Clamp the AC current probe around the output conductor for "Phase A" in order to take a reading.

35. Enter the value from step 34 in the "Enter Calibration Point" field.

36. Click on "OK".

    The System will again process Calibration and the system will prompt you to "Enter Calibration Point for Current in Phase B" automatically. The "Calibration Group Status" window will display "Calibration complete but not saved for the current out of Phase A".

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Illustration 13	g00841140

37. Clamp the AC current probe around the output conductor for "Phase B" in order to take a reading.

    Reference: Refer to Illustration 14.

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

39. Click on "OK".

    The System will again process Calibration and the system will prompt you to "Enter Calibration Point for Current in Phase C" automatically. The "Calibration Group Status" window will display "Calibration complete but not saved for the current out of Phase B".

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Illustration 14	g00841147

40. Clamp the AC current probe around the output conductor for "Phase C" in order to take a reading.

    Reference: Refer to Illustration 15.

41. Enter the value from step 40 in the "Enter Calibration Point" field.

42. Click on "OK".

    The System will again process Calibration and the system will prompt you to "Enter Calibration Point for Current in Phase A" automatically. The "Calibration Group Status" window will display "Calibration complete but not saved for the current out of Phase C".

43. Click on "Save" on the "Calibration of a channel" window.

    You will hear the input contactors and output contactors open.

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

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Illustration 15	g01003513

44. To end the calibration in UPS View, click on "Connection" that is located on the menu bar and select "Disconnect".

    You will stop receiving the telemetry data.

45. Unplug the RS232 cable from the System Input/Output and Isolation Board. Replace the Sheet Metal.

46. Close the doors for proper air flow into the System.