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


Interface Board - Remove and Install - Flywheel Interface Board

Usage:

UPS 250 APZ


Old Flywheel Interface Board - Removal Procedure




Illustration 1g00850805

  1. Disconnect the 24 V power cable from "J1" (10).

  1. Disconnect the APC ribbon cable from "J3" (8) .

  1. Disconnect the APC ribbon cable from "J2" (7) .

  1. Disconnect the cable for the vacuum sensor from "J10" (5) .

  1. Disconnect the cable for the top bearing thermistor from "J7" (4) .

  1. Disconnect the top flywheel harness from "J5" (3) .

  1. Disconnect the Comm/Accel ribbon cable from "J9" (9) .

  1. Disconnect the cable for the bottom bearing thermistor from "J6" (2) .

  1. Disconnect the bottom flywheel harness from "J4" (1) .

    Note: If the flywheel interface board is being replaced with a board with the same revision, proceed to "Old Flywheel Interface Board - Installation Procedure".

    Note: If the flywheel interface board is being replaced with a board with a newer revision, proceed to "Cable and Harness - Removal Procedure".

Cable and Harness - Removal Procedure

Note: Use this procedure if the flywheel interface board is being replaced with a board with a newer revision.

  1. Remove yellow cables for the thermistor that are located at the top and bottom of the flywheel.

  1. Put the cables aside.

  1. Remove harnesses from the top and the bottom of the flywheel and set aside.

  1. Remove the three mounting screws on the flywheel interface board and remove the board.

  1. Proceed to "New Flywheel Interface Board - Installation Procedure".

Old Flywheel Interface Board - Installation Procedure

  1. Install the flywheel interface board.

  1. Install the three mounting screws on the flywheel interface board.

  1. Connect the bottom harness for the flywheel to "J4" (10) .

  1. Connect the cable for the bottom bearing thermistor to "J6" (2) .

  1. Connect the Comm/Accel ribbon cable to "J9" (9) .

  1. Connect the cable for the top bearing thermistor to "J7" (4) .

  1. Connect the cable for the vacuum sensor to "J10" (5) .

  1. Connect the APC ribbon cable to "J2" (7) .

  1. Connect the APC ribbon cable to "J3" (8) .

  1. Connect the 24 V power cable to "J1" (10) .

  1. Calibrate the hall effect sensors.

    Proceed to Systems Operation, Testing and Adjusting, "Flywheel Telemetry - Calibrate".

New Flywheel Interface Board - Removal Procedure

Note: This procedure is for units with Load Cells in the Flywheel.




Illustration 2g00850747

  1. Disconnect the 24 V power cable from "J1" (11) .

  1. Disconnect the Comm/Accel ribbon cable from "J9" (3) .

  1. Disconnect the APC ribbon cable from "J3" (10) .

  1. Disconnect the APC ribbon cable from "J2" (7) .

  1. Disconnect the bottom flywheel harness from "J4" (1) .

  1. Disconnect the cable for the bottom bearing thermistor from "J6" (2) .

  1. Disconnect the wiring harness for the top of the flywheel from "J5" (4) .

  1. Disconnect the cable for the top bearing thermistor from "J7" (5) .

  1. Disconnect the cable for the vacuum sensor from "J10" (6) .

  1. Loosen all screws (8) .

  1. Disconnect the bottom flywheel harness ground lug from "J13" (12) .

  1. Disconnect the top flywheel harness ground lug from "J12" (9) .

  1. Remove the board from the chassis.

New Flywheel Interface Board - Installation Procedure

Note: The cables have shielding and the end of the shield is equipped with a tab that must be in electrical contact with the chassis. These tabs will be installed as the board is mounted.

  1. Attach the new board to the chassis by using the uppermost mounting hole. Do not tighten this screw completely.

  1. Connect the top flywheel harness ground lug to "J12" (9) .

  1. Connect the bottom flywheel harness ground lug to "J13" (12) .

  1. Tighten all screws in order to secure the board in place.

  1. Connect the cable for the vacuum sensor to "J10" (6) .

  1. Connect the cable for the top bearing thermistor to "J7" (5) .

  1. Connect the top flywheel wiring harness to "J5" (4) .

  1. Connect the cable for the bottom bearing thermistor to "J6" (2) .

  1. Connect the bottom flywheel harness to "J4" (1) .

  1. Connect the APC ribbon cable to "J2" (7) .

  1. Connect the APC ribbon cable to "J3" (10) .

  1. Connect the Comm/Accel ribbon cable to "J9" (3) .

  1. Connect the 24 V power cable to "J1" (11) .

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