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


Flywheel Telemetry - Calibrate

Usage:

UPS 250 APZ


Calibration Procedure for Hall Effect Probe Flywheel Telemetry

This procedure is performed in order to adjust the measured flux densities inside the flywheel assembly. This procedure is also performed in order to adjust the measured field coil current to both of the field coils.

This calibration only applies to equipment with the Hall Effect Probes and not having a Load Cell.

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

In order to perform the calibration, the flywheel must be stopped. In order to perform the calibration, the flywheel should also be indicating 0 RPM.

Determine the type of Bearing of the Hall Effect Probe

There are two different kinds of bearings in a Hall Effect Probe: Non-EVD and EVD. An EVD bearing is a bearing with a rubber O-ring on the outside cartridge of the bearing.

The type of bearing is determined by the serial number of the lower bearing. With a mirror, locate the serial number on the underside of the lower bearing.

Calibration Procedure for Non-EVD Bearing

------ WARNING! ------

Risk of electric shock or energy hazard. Parts inside this UPS are energized by the flywheel even when the AC power is disconnected.


  1. Connect a personal computer to the UPS via the serial (direct) connection. Enter your password. Refer to the Systems Operation, Testing and Adjusting, RENR9988, "Personal Computer to UPS Connection".

  2. Place the keyswitch in the BYPASS position for the MMU that is being calibrated.

    Note: In a SMS system, place the keyswitch on the System cabinet (cabinet of the flywheel) to the BYPASS position.

  3. For a MMS system, rotate the switch on the Parallel Cabinet Interface board (PCI) to the corresponding MMU.

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

  5. Remove the Top Rear Center vacuum plug from the flywheel in order to measure Top Flux Density 1.

  6. Remove the Top Front Center vacuum plug from the flywheel in order to measure Top Flux Density 2.

  7. Remove the Bottom Front Center vacuum plug from the flywheel in order to measure Bottom Flux Density 1.

  8. Remove the Bottom Rear Center vacuum 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.

  9. 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.

  10. Turn on your Personal Computer.

  11. Run UPSView by double clicking on the icon (4) on your PC.

  12. In UPSView, click on the "Calibrate" menu item.


    Illustration 1g01273072
    Flywheel Telemetry

  13. 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.

  14. Press the "View Status" button.

    Another "Calibration Group Status" window will open. If this window blocks your view of "Calibration of a Channel" window, drag this window aside.

  15. Press the "Use Defaults" button.

    The "Calibration of a Channel" window is asking for the measurement of "Minimum Top Field Coil Current ".

  16. 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.

  17. Measure the Top Field Coil Current.

  18. Enter the value that is displayed on the meter in the "Enter Calibration Point" field. This value should be zero Ampere.

  19. Click the "OK" button.

    The system will process the calibration. The system will automatically ramp the current to approximately five Amperes.

    The "Calibration of a Channel" window will automatically change. Enter the measurement for the Maximum Field Coil Current.

  20. Measure the Top Field Coil Current.

  21. Enter the value that is displayed on the meter in the "Enter Calibration Point" field. This value should be near five Amperes.

  22. Click the "OK" Button.

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

    The "Calibration of a Channel" window will automatically change. Enter the measurement for the Minimum Bottom Field Coil Current.

  23. Clamp the DC Current probe around the conductor for the positive terminal of the Bottom Field Coil (BFC) in order to take a reading.

  24. Measure the Bottom Field Coil Current.

  25. Enter the value that is displayed on the meter in the "Enter Calibration Point" field. This value should be near zero Ampere.

  26. Click the "OK" Button. The "View Status" window will change in order to reflect the completion of this step.

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

    The system will process the calibration. The system will automatically ramp the current to approximately five Amperes.

    The "Calibration of a Channel" window will automatically change. The "Maximum" Button on "Calibration of a Channel" window gets selected automatically. Enter the "Maximum Bottom Field Coil Current" measurement.

  27. Measure the Bottom Field Coil Current.

  28. Enter the value that is displayed on the meter in the location "Enter Calibration Point". This value should be near five Amperes.

    The system will prompt you to "Enter Calibration Point" for the Top Flux Density 1 automatically. Enter the "Minimum Top Flux Density 1" measurement.

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



    Illustration 2g01273128

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

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


    Illustration 3g01273132

  30. 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 4g01273136

  31. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor.

    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.

  32. Measure the Top Flux Density at the Top 1 position.

    Note: A typical value would be 0.026 DC Tesla.

  33. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the Top Flux Density 1.

  34. Click the "OK" Button.

    The system will process the calibration. The system automatically ramps the field coil current to approximately five Amperes. The readings from the Gaussmeter will change. The reading will become stable when the current reaches the maximum.

    The "Calibration of a Channel" window will automatically change. Enter the "Maximum Top Flux Density 1" measurement.

  35. Measure the Top Flux Density at the Top 1 position.

    Note: A typical value would be 0.256 DC Tesla.

  36. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the Top Flux Density 1.

  37. Click the "OK" Button.

    The "Calibration of a Channel" window will automatically change. Enter the "Minimum Top Flux Density 2" measurement.

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

  38. Insert the probe to the Gaussmeter into the Top Front Center port in order to measure Top Flux Density 2. Refer to Illustration 2.

  39. 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. Refer to Illustration 3.

  40. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 4.

    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.

  41. Measure the Top Flux Density at the Top 2 position.

    Note: A typical value would be 0.026 DC Tesla.

  42. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the Top Flux Density 2.

  43. Click the "OK" Button.

    The system will process the calibration. The system automatically ramps the field coil current to approximately five Amperes. The readings from the Gaussmeter will change. The reading will become stable when the current reaches the maximum.

    The "Calibration of a Channel" window will automatically change. Enter the "Maximum Top Flux Density 2" measurement.

  44. Measure the Maximum Flux Density at the Top 2 position.

    Note: A typical value would be 0.256 DC Tesla.

  45. Enter the value that is displayed on the meter in the "Enter Calibration Point" for the Top Flux Density 2.

  46. Click the "OK" Button.

    The "Calibration of a Channel" window will automatically change. Enter the "Minimum Bottom Flux Density 1" measurement.

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

  47. Insert the probe to the Gaussmeter into the Bottom Front Center port in order to measure Bottom Flux Density 1. Refer to Illustration 2.

  48. 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. Refer to Illustration 3.

  49. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 4.

    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.

  50. Measure the Bottom Flux Density at the Bottom 1 position.

    Note: A typical value would be 0.030 DC Tesla.

  51. Enter the value that is displayed on the meter in the location "Enter Calibration Point" for "Bottom Flux Density 1".

  52. Click the "OK" Button.

    The system will process the calibration. The system automatically ramps the field coil current to approximately five Amperes. The readings from the Gaussmeter will change. The reading will become stable when the current reaches the maximum.

    The "Calibration of a Channel" window will automatically change. Enter the "Maximum Bottom Flux Density 1" measurement.

  53. Measure the Bottom Flux Density at the Bottom 1 position.

    Note: A typical value would be 0.310 DC Tesla.

  54. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the Bottom Flux Density 1.

  55. Click the "OK" Button.

    The "Calibration of a Channel" window will automatically change. Enter the "Minimum Bottom Flux Density 2" measurement.

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

  56. Insert the probe to the Gaussmeter into the Bottom Rear Center port in order to measure "Bottom Flux Density 2". Refer to Illustration 2.

  57. 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. Refer to Illustration 3.

  58. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 4.

    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.

  59. Measure the "Bottom Flux Density" at the Bottom 2 position.

    Note: A typical value would be 0.030 DC Tesla.

  60. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the "Bottom Flux Density 2".

  61. Click the "OK" Button.

    The system will process the calibration. The system automatically ramps the field coil current to approximately five Amperes. The readings from the Gaussmeter will change. The reading will become stable when the current reaches the maximum.

    The "Calibration of a Channel" window will automatically change. Enter the "Maximum Bottom Flux Density 2" measurement.

  62. Measure the "Bottom Flux Density" at the Bottom 2 position.

    Note: A typical value would be 0.310 DC Tesla.

  63. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the "Bottom Flux Density 2".

  64. Click the "OK" Button.

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

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

    Note: This reading should be approximately fifteen Amperes.

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

  67. Click "OK".

    The system will process the calibration. The system automatically drops the field coil current to zero. The field current will raise to approximately fifteen Amperes. The system will prompt you to "Enter Calibration Point" for the "Bottom Field Coil Current".

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

    Note: This reading should be approximately fifteen Amperes.

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

  70. Click "OK".

    The system will process the calibration. The system will drop the field coil current to zero. The field coil current will raise to fifteen Amperes.

    The "Calibration of a Channel" window will automatically change. Enter the "Enter Calibration Point" for the Maximum Top Flux Density 1.

  71. Insert the probe of the Gaussmeter into the Top Rear Center port in order to measure Top Flux Density 1. Refer to Illustration 2.

  72. 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. Refer to Illustration 3.

  73. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 4.

    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.

  74. Measure the Top Flux Density at the Top 1 position.

    Note: A typical value would be 0.780 DC Tesla.

  75. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the "Top Flux Density 1".

  76. Click the "OK" Button.

    The system will process the calibration. The system will drop the field coil current to zero. The field coil current will raise to fifteen Amperes.

    The "Calibration of a Channel" window will automatically change. Enter the "Enter Calibration Point" for the "Maximum Top Flux Density 2".

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

  78. 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. Refer to Illustration 3.

  79. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 4.

    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.

  80. Measure the Top Flux Density at the Top 2 position.

    Note: A typical value would be 0.780 DC Tesla.

  81. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the "Top Flux Density 2".

  82. Click the "OK" Button.

    The difference between the value for the "Top Flux Density 1" and the value for "Top Flux Density 2" should be less than 0.300 Tesla.

    If the difference is greater than 0.300 Tesla, exit this procedure. Repeat the procedure starting at Step 2. If the difference is less than 0.300 continue with the steps in this procedure.

    The system will process the calibration. The system will drop the field coil current to zero. The field coil current will raise to fifteen Amperes.

    The "Calibration of a Channel" window will automatically change. Enter the "Enter Calibration Point" for the "Maximum Bottom Flux Density 1".

  83. Insert the probe of the Gaussmeter into the Bottom Front Center port in order to measure "Bottom Flux Density 1". Refer to Illustration 2.

  84. 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. Refer to Illustration 3.

  85. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap for the rotor. Refer to Illustration 4.

    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.

  86. Measure the Bottom Flux Density at the Bottom 1 position.

    Note: A typical value would be 0.800 DC Tesla.

  87. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the "Bottom Flux Density 1".

  88. Click the "OK" Button.

    The system will process the calibration. The system will drop the field coil current to zero. The field coil current will raise to fifteen Amperes.

    The "Calibration of a Channel" window will automatically change. Enter the "Enter Calibration Point" for the "Maximum Bottom Flux Density 2".

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

  90. 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. Refer to Illustration 3.

  91. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 4.

    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.

  92. Measure the Bottom Flux Density at the Bottom 2 position.

    Note: A typical value would be 0.800 DC Tesla.

  93. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the "Bottom Flux Density 2".

  94. Click the "OK" Button.

    The difference between the value for the "Bottom Flux Density 1" and the "Bottom Flux Density 2" should be less than 0.300 Tesla.

    If the difference is greater than 0.300 Tesla, exit this procedure. Repeat the procedure starting at Step 2. If the difference is less than 0.300 continue with the steps in this procedure.

  95. Clean the O-rings on the vacuum plugs. Apply a small amount of High Vacuum grease to the O-rings.

  96. Install the four O-rings vacuum plugs.

  97. Close the release valve for the vacuum for the flywheel.

  98. Start the vacuum pump.

  99. Click on "Save" on the "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 window of UPSView. This indicates that the Calibration has been successfully completed.

  100. Disconnect UPSView by clicking on "Connection" on the menu bar and select "Disconnect".

    You will stop receiving the system telemetry.

  101. Unplug the RS232 cable from the SIO board.

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

    This calibration is complete.

    Note: Listen for a "thunking" sound when the flywheel returns to on-line status. If the sound is apparent, the rotor has "hopped". The calibration must be repeated.

Calibration Procedure for EVD Bearing

Note: This procedure is for Systems with EVD Bearings. Perform this procedure whenever the following boards are replaced: Flywheel Interface Board, System Controller Board and Field Coil Driver Board .

------ WARNING! ------

Risk of electric shock or energy hazard. Parts inside this UPS are energized by the flywheel even when the AC power is disconnected.


This procedure involves working in an energized cabinet. De-energize the cabinet while components are being removed from the flywheel. The cabinet should then be energized in order to begin the calibration.

The MMS System should be in BYPASS when an MMU is turned on. The MMS System should be in BYPASS when an MMU is turned off with the isolation switches.

  1. Connect a personal computer to the UPS via serial (direct) connection. Enter your password. For further instructions, refer to Systems Operation, Testing and Adjusting, RENR9988, "Personal Computer to UPS Connection".

  2. Place the keyswitch in the BYPASS position for the MMU that is being calibrated.

    Note: In a Single-Module System, place the keyswitch in the BYPASS position on the System Cabinet.

  3. For a MMS system, rotate the switch on the Parallel Cabinet Interface board (PCI) to the corresponding MMU.

  4. Switch off the vacuum pump.

    Remove the Vacuum Plugs. Remove the Settle Bearing.

  5. Remove the Top Rear Center vacuum plug from the flywheel in order to measure the Top Flux Density 1.

  6. Remove the Top Front Center vacuum plug from the flywheel in order to measure Top Flux Density 2.

  7. Disconnect the ribbon cable and remove the ribbon cable from the "Comm/Accel" board.

  8. Remove the "Comm/Accel" board from the upper bearing cartridge. Refer to Systems Operation, Testing and Adjusting, RENR9988, "Rotor Position Sensor Assembly".

  9. 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.

  10. 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.

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

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

  13. Insert all four shims for the rotor into the four bottom SAE ports.

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

    Note: Do not remove the bearing.

  15. 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).

  16. Remove the Bottom Front Center vacuum plug from the flywheel in order to measure Bottom Flux Density 1.

  17. Remove the Bottom Rear Center vacuum 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.

  18. 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.

  19. Turn on your Personal Computer.

  20. In UPSView, click on the "Calibrate" menu item.

  21. Select "Flywheel Telemetry".

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



    Illustration 5g01274307
    Flywheel Telemetry

  22. Press the "View Status" Button.

    Another "Calibration Group Status" window will open. If this window blocks your view of "Calibration of a Channel" window, drag this window aside.

  23. 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.

  24. 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.

  25. Measure the Top Field Coil Current.

  26. Enter the value that is displayed on the meter in the "Enter Calibration Point" field. This value should be zero Ampere.

  27. 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".

  28. Measure the Top Field Coil Current.

  29. Enter the value that is displayed on the meter in the "Enter Calibration Point" field. This value should be near five Amperes.

  30. Click the "OK" Button.

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

  31. Clamp the DC Current probe around the conductor for the positive terminal of the Bottom Field Coil (BFC) in order to take a reading.

  32. Measure the Bottom Field Coil Current. This reading should be zero.

  33. Enter the value that is displayed on the meter in the "Enter Calibration Point" field. This value should be near 0 Ampere.

  34. Click the "OK" Button.

    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 five 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.

  35. Measure the Bottom Field Coil Current.

  36. Enter the value that is displayed on the meter in the "Enter Calibration Point" field. This value should be near five Amperes.

    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 6g01274108

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

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


    Illustration 7g01274110

  38. 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 8g01274111

  39. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor.

    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.

  40. Measure the "Top Flux Density at the Top 1" position.

    Note: A typical value would be 0.026 DC Tesla.

  41. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the "Top Flux Density 1".

  42. Click the "OK" Button.

    The System will process the calibration. The system automatically ramps the field coil current to approximately five 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". Enter the measurement for "Maximum Top Flux Density 1".

  43. Measure the Top Flux Density at the Top 1 position.

    Note: A typical value would be 0.256 DC Tesla.

  44. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the Top Flux Density 1.

  45. Click the "OK" Button.

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

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

  46. Insert the probe to the Gaussmeter into the Top Front Center port in order to measure "Top Flux Density 2". Refer to Illustration 6.

  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. Refer to Illustration 7.

  48. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 8.

    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.

  49. Measure the Top Flux Density at the Top 2 position.

    Note: A typical value would be 0.026 DC Tesla.

  50. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the Top Flux Density 2.

  51. Click the "OK" Button.

    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". Enter the measurement for "Maximum Top Flux Density 2".

  52. Measure the Maximum Flux Density at the Top 2 position.

    Note: A typical value would be 0.256 DC Tesla.

  53. Enter the value that is displayed on the meter in the "Enter Calibration Point" field for the Top Flux Density 2.

  54. Click the "OK" Button.

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

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

  55. Insert the probe to the Gaussmeter into the Bottom Front Center port in order to measure Bottom Flux Density 1. Refer to illustration 6.

  56. 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. Refer to illustration 7.

  57. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to illustration 8.

    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.

  58. Measure the Bottom Flux Density at the Bottom 1 position.

    Note: A typical value would be 0.030 DC Tesla.

  59. Enter the value that is displayed on the meter in the location "Enter Calibration Point" for "Bottom Flux Density 1".

  60. Click the "OK" Button.

    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". Enter the measurement "Maximum Bottom Flux Density 1".

  61. Measure the Bottom Flux Density at the Bottom 1 position.

    Note: A typical value would be 0.310 DC Tesla.

  62. Enter the value that is displayed on the meter in the location "Enter Calibration Point" for Bottom Flux Density 1.

  63. Click the "OK" Button.

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

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

  64. Insert the probe to the Gaussmeter into the Bottom Rear Center port in order to measure Bottom Flux Density 2. Refer to Illustration 6.

  65. 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. Refer to Illustration 7.

  66. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap for the rotor. Refer to Illustration 8.

    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.

  67. Measure the Bottom Flux Density at the Bottom 2 position.

    Note: A typical value would be 0.030 DC Tesla.

  68. Enter the value that is displayed on the meter in the location "Enter Calibration Point" for Bottom Flux Density 2.

  69. Click the "OK" Button.

    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". Enter the measurement "Maximum Bottom Flux Density 2".

    Note: A typical value would be 0.310 DC Tesla.

  70. Enter the value that is displayed on the meter in the location "Enter Calibration Point" for Bottom Flux Density 2.

  71. Click the "OK" Button.

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

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

    Note: This reading should be approximately fifteen Amperes.

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

  74. Click "OK".

    The system will process the calibration. The system automatically drops the field coil current to zero. The current will raise to approximately fifteen Amperes. The system will prompt you to "Enter Calibration Point" for the "Bottom Field Coil Current".

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

    Note: This reading should be approximately fifteen Amperes.

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

  77. Click "OK".

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

  78. Insert the probe of the Gaussmeter into the Top Rear Center port in order to measure Top Flux Density 1. Refer to Illustration 6.

  79. 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. Refer to Illustration 7.

  80. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 8.

    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.

  81. Measure the Top Flux Density at the Top 1 position.

    Note: A typical value would be 0.780 DC Tesla.

  82. Enter the value that is displayed on the meter in the location "Enter Calibration Point" for Top Flux Density 1.

  83. Click the "OK" Button.

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

  84. Insert the probe of the Gaussmeter into the Top Front Center port in order to measure Top Flux Density 2. Refer to Illustration 6.

  85. 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. Refer to Illustration 7.

  86. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 8.

    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.

  87. Measure the Top Flux Density at the Top 2 position.

    Note: A typical value would be 0.780 DC Tesla.

  88. Enter the value that is displayed on the meter in the location "Enter Calibration Point" for Top Flux Density 2.

  89. Click the "OK" Button.

    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 Systems Operation, Testing and Adjusting, RENR9988, "Flywheel Telemetry - Calibrate" procedure.

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

  90. Insert the probe of the Gaussmeter into the Bottom Front Center port in order to measure Bottom Flux Density 1. Refer to Illustration 6.

  91. 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. Refer to Illustration 7.

  92. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 8.

    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.

  93. Measure the Bottom Flux Density at the Bottom 1 position.

    Note: A typical value would be 0.800 DC Tesla.

  94. Enter the value that is displayed on the meter in the location "Enter Calibration Point" for Bottom Flux Density 1.

  95. Click the "OK" Button.

    The system will process the calibration. The system will drop the field coil current to zero. The system automatically raises the field coil current to fifteen Amperes.

    The system will process the calibration. The system will drop the field coil current to zero. The system automatically raises the field coil current to fifteen Amperes.

  96. Insert the probe of the Gaussmeter into the Bottom Rear Center port in order to measure Bottom Flux Density 2. Refer to Illustration 6.

  97. 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. Refer to Illustration 7.

  98. Rotate the probe slowly until the tip of the probe slides underneath the pole ring and the gap of the rotor. Refer to Illustration 8.

    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.

  99. Measure the Bottom Flux Density at the BOTTOM 2 position.

  100. Enter the value that is displayed on the meter in the location "Enter Calibration Point" for Bottom Flux Density 2.

    Note: A typical value would be 0.800 DC Tesla.

  101. Click the "OK" Button.

    The difference between the value for the "Bottom Flux Density 1" and the value for the "Bottom Flux Density 2" should be less than 0.300.

    If the difference is greater than 0.300 Tesla, exit this procedure, and repeat Systems Operation, Testing and Adjusting, RENR9988, "Flywheel Telemetry - Calibrate". Otherwise continue with closing steps in this procedure.

  102. Clean the O-rings on the vacuum plugs. Apply a small amount of High Vacuum grease to the O-rings.

  103. Install the four O-rings vacuum plugs.

  104. Close the release valve for the vacuum of the flywheel.

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

    You will hear the Input Contactor "K1" open.

    The calibration ends. The message "Flash reprogrammed OK" will appear on the text window of UPSView. This indicates that the Calibration has been successfully completed.

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

    You will stop receiving the system telemetry.

  107. Unplug the RS-232 cable from the SIO board.

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

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

  110. Install the spacer and the castle nut.

  111. Clean the threads of 76.20 mm (3/8 inch)stainless bolts or replace the bolts with new bolts.

  112. Place one drop of bearing mount compound on the bolt threads.

  113. Install the bolt. Tighten the bolt to 38 N·m (28 lb ft).

  114. Apply High Vacuum Grease to the O-ring for the "Comm/Accel" board.

  115. 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.

  116. Install the three screws.

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

  118. Reinstall O-rings to the plugs.

  119. Reinstall the eight screws for the bottom bearing cartridge. Tighten the eight screws to 27 N·m (20 lb ft).

  120. Remove all four shims for the rotor.

  121. Apply High Vacuum Grease to the vacuum hose.

  122. Reinstall the vacuum hose and the brass fitting into the bottom of the flywheel housing.

  123. Remove the O-rings from the five SAE plugs. Grease the O-rings with High Vacuum Grease.

  124. Reinstall the remaining five SAE Plugs. Install two of the bolts in the upper half of the flywheel. Install three of the bolts in the lower half of the flywheel.

  125. Turn on the vacuum pump.

  126. Recalibrate the RPS sensor. Refer to Systems Operation, Testing and Adjusting, RENR9988, "RPS Advance Setpoint Calibration".

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

    This calibration is complete.

Note: Listen for a "thunking" sound when the flywheel returns to on-line status. If the sound is apparent, the rotor has "hopped". The calibration must be repeated.

Caterpillar Information System:

TA22-4WD Agricultural Transmission Breather (Transmission) - Clean
UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies Flywheel Field Coil Current - Calibrate
2006/05/29 New Cylinder Head Groups are Used {1100}
C7 and C9 On-highway Engines Engine Oil and Filter - Change
UPS 1000S/ UPS 1200S Uninterruptible Power Supplys General Information (Maintenance Bypass Cabinet)
2006/05/22 Wiring for the Coolant Level Switches and the Coolant Level Sensors {7422}
UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies System Output Current - Calibrate
UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies Door Latch
UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies Door Pull and Retaining Ring
C280 Marine Auxiliary Engines System Overview
UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies Door
UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies General Information (Cabinet Hardware)
C7 and C9 On-highway Engines Engine Oil Level Gauge - Calibrate
3408E and 3412E Industrial Engines Piston and Rings
3408E and 3412E Industrial Engines Piston and Rings
UPS 1000S/ UPS 1200S Uninterruptible Power Supplys Internal Component Preremoval Steps (Maintenance Bypass Cabinet)
UPS 1000S/ UPS 1200S Uninterruptible Power Supplys System Fuse (Maintenance Bypass Cabinet)
UPS 1000S/ UPS 1200S Uninterruptible Power Supplys Bypass Pushbutton
C4.4 Industrial Engine Gear Group - Inspect
UPS Firmware Enhancement for Monitoring Bearing Serviceability{4480, 7551, 7620} UPS Firmware Enhancement for Monitoring Bearing Serviceability{4480, 7551, 7620}
C4.4 Industrial Engine Flywheel - Inspect
C13 and C15 On-highway Engines Data Link - Test
C4.4 Industrial Engine Flywheel Housing - Inspect
TA22-4WD Agricultural Transmission Lifting and Tying Down the Transmission
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.