UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies Caterpillar


System Overview

Usage:

UPS 250 APZ


Introduction



Illustration 1g01266139

The system is a three-phase Uninterruptible Power Supply (UPS). The system uses a flywheel to store energy mechanically in the form of a rotating mass. During normal operation, the flywheel will be rotating at a constant speed. The typical speed of the flywheel is 7700 RPM. The power from a utility will be delivered by the system to an external load. When power from the utility is interrupted, the system will convert the mechanical energy that is stored in the flywheel to electrical energy. This energy will be used by the external load. When the power from the utility is available again, the system will transfer the load back to the power from the utility.

Diagram Overview of Components (UPS)



Illustration 2g01254252
Diagram of Components (UPS)
(1) Input node
(2) Input contactor
(3) Static switch
(4) Bypass contactor
(5) Inverter node
(6) Output contactor
(7) Output node
(8) Field coil driver
(9) Flywheel inverter
(10) DC bus
(11) Utility Inverter

Illustration 2 shows a simplified diagram of the system. The nodes that are shown in Illustration 2 are in the following list: Input Node (1), Inverter Node (5) and Output Node (7).

The nodes determine the state of the system. The input node (1) and the output node (7) are externally available. These nodes are used in order to attach the system to a power source and to the load. The inverter node (5) is used internally by the system.

The DC Bus (10) is also identified in Illustration 2. The DC Bus (10) is used as a power source for the field coil currents. The mode of the system determines one of the following:

  • If the bus is used as a power source for the flywheel

  • If the bus is used as a power source for the utility inverters

The main functional blocks are shown in Illustration 2. A description of each function is in the following list:

Input Contactor (2) - A mechanical contactor that is used to control the flow of electricity into the system

Static Switch (3) - The switch is a semiconductor device (thyristor). The Static Switch is used to isolate the system from the utility grid when an outage occurs.

Bypass Contactor or Breaker (4) - A device that is used to connect electrically the input source to the load without going through the UPS

Output Contactor (6) - A mechanical contactor that is used to control the flow of electricity to the load

Field Coil Driver (8) - The Field Coil Driver is a semiconductor device that is used to drive current through the field coils. The field coils are used to generate magnetic forces that act upon the flywheel. These forces are controlled in order to provide a lifting force on the flywheel. The force prolongs the life of the bearings.

Flywheel Inverter (9) - The Flywheel Inverter is a semiconductor device that is used to convert the voltage from the DC Bus into AC signals. When the power from the utility is not available, the flywheel inverter will rectify AC signals from the flywheel to the DC Bus.

Utility Inverter (11) - The utility inverter is a semiconductor device that is used to rectify the AC voltage that is on the filter node. The AC voltage is rectified into a DC voltage. When the power from the utility is lost, the utility inverter will convert the voltage from the DC Bus to the operating voltage and frequency of the system.

Single Module System (SMS)



Illustration 3g01254318
SMS One-Line diagram


Illustration 4g01266334
SMS cabinet layout
(12) Bypass cabinet
(13) Flywheel cabinet

The UPS 120/150 and 250i/300 SMS systems are distinguished from the MMS systems by a single flywheel multiple module unit (MMU) cabinet. The (MMU) cabinet is bolted to a bypass cabinet.

The width of the bypass cabinet can be two different sizes. The size is determined by a three-wire system or by a four-wire system. The cabinet for the four-wire system is wider than the cabinet for the three-wire system.

Multiple Module System (MMS)



Illustration 5g01254320
MMS One-Line diagram - max four (4) flywheels


Illustration 6g01266524
UPS250iE/ 300E MMS cabinet layout
(14) I/O cabinet
(15) System cabinet
(16) Flywheel (MMU) cabinet

The UPS 250iE/300E MMS systems are distinguished from the other MMS systems by including one Flywheel (MMU) cabinet along with an Input/Output (I/O) cabinet.

The "E" in UPS 300E stands for "expandable" to differentiate the cabinet from the SMS UPS 300 cabinet arrangement. An expandable system can have an MMU cabinet added if expanded run time or more power is required.



Illustration 7g01266675
UPS250i (N+1)/ UPS300 (N+1)/ UPS500/ UPS600 cabinet layout

The UPS 250i (N+1)/300 (N+1)/500/600 MMS systems are distinguished from the other MMS systems by the following:

  • Inclusion of two flywheel (MMU) cabinets

  • Inclusion of an I/O cabinet

  • Inclusion of as system cabinet

The (N+1) configuration denotes a redundant system that is sized with one more MMU than is required to supply the fully rated system load.



Illustration 8g01266739
UPS500 (N+1)/ UPS600 (N+1)/ UPS750/ UPS900 cabinet layout

The UPS 500 (N+1)/600 (N+1)/750/900 MMS systems are distinguished from the other MMS systems by the following:

  • Inclusion of three flywheel (MMU) cabinets

  • Inclusion of a flywheel (MMU)

  • Inclusion of an I/O cabinet

  • Inclusion of as system cabinet

The (N+1) configuration denotes a redundant system that is sized with one more MMU than is required to supply the fully rated system load.



Illustration 9g01266789
UPS750 (N+1)/ UPS900 (N+1) cabinet layout

The UPS750 (N+1)/900 (N+1) MMS systems are distinguished from the other MMS systems by the following:

  • Inclusion of four flywheel (MMU) cabinets

  • Inclusion of an I/O cabinet

  • Inclusion of a system cabinet

The (N+1) configuration denotes a redundant system that is sized with one more MMU than is required to supply the fully rated system load.

The UPS301 is the field expansion cabinet that can be added after installation to existing UPS250iE, UPS300E, UPS500, UPS600, UPS750, and UPS900. The UPS301 field expansion cabinet is a flywheel cabinet.

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