Instructions For Converting Uninterruptible Power Supplys With Hall Effect Probes To The G3.5 Load Cell{4480} Caterpillar

Uninterruptible Power Supply:

UPS 1000S (S/N: CZS1-UP)

UPS 1200S (S/N: CZT1-UP)

UPS 150 (S/N: CPC1-UP)

UPS 250 (S/N: CNM1-UP; APZ1-UP)

UPS 300 (S/N: CNJ1-UP; CPZ1-UP)

UPS 500 (S/N: CSE1-UP)

UPS 600 (S/N: CTX1-UP)

UPS 750 (S/N: CPM1-UP)

UPS 900 (S/N: CRY1-UP)

Introduction

The information in this Special Instruction guides the user through the procedure for removing and installing the bearings on the Uninterruptible Power Supplys that are listed above. Additionally, the instructions that follow will upgrade the Uninterruptible Power Supplys with Hall Effect Probes to Load Cells.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

Firmware Requirements

Note: All Firmware must be revision 3.56/3.59 or higher. Upgrade to the latest revision before proceeding.

Procedure

Illustration 1	g01953478
(1) Screw for Rotor Position Sensor (2) Rotor Position Sensor (3) O-ring for Rotor Position Sensor (4) Retaining Bolt for Rotor (5) Serrated Rotor Wheel (6) Bearing Bolt (7) Upper Bearing Cartridge (8) Hex Plug (9) Shim Pack (10) O-ring (11) Flywheel Housing (12) Lower Bearing Cartridge (13) Rotor Retainer (14) Polished Retaining Bolt for Rotor (15) Load Cell (16) Screws for Load Cell

Pre-Removal Steps

Bearing service is always performed on both the upper and lower bearings.

Note: Always change the lower bearing first, then change the upper bearing.

Note: These steps are defined for electrical high risk maintenance of the cabinet components located behind the locked doors. Follow these steps before performing maintenance on internal components. It is necessary to shut down all input to the Flywheel Cabinet for this operation both AC and DC. The customer load will be unprotected.

Note: This cabinet has two sources of voltage. Control AC voltage and the DC Bus.

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When servicing or repairing electric power generation equipment: Make sure the unit is either locked out or tagged DO NOT OPERATE. Remove all fuses. Make sure the generator engine is stopped. Make sure all batteries are disconnected. Make sure all capacitors are discharged. Make sure residual voltage in the rotor, stator and the generator is discharged. Failure to do so could result in personal injury or death.

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When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE. Remove all fuses.

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Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Use electrical safety gloves when you are working in the cabinets. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.

1. Brake the flywheel. Execution of this command can be performed using the Ctrl-X keystrokes in UPSView.

2. Turn the keyswitch to the "Spindown/Offline" position.

3. Transfer the UPS/SMS or MMU to bypass mode.

   The UPS/SMS or MMU needs to be put into the bypass mode before any work is done to the cabinet. Refer to Testing and Adjusting, "Transfer to Bypass Mode".

4. Discharge the DC Bus. Let the DC Bus bleed down to below 24VDC.

5. Open the doors of the cabinet by using a 5/16-inch hex key on the upper and lower latches.

6. Disconnect the DC bus by using the DC Disconnect Handle on the middle metal safety shield.

   Note: Verify the green light is on before operating the DC Disconnect Switch Handle.

7. Open the circuit breaker (CB1) that is located on the lower left panel on the Flywheel Cabinet.

8. Discharge the capacitors by allowing the capacitor banks in the UPS/SMS or MMU to bleed down for ten minutes.

9. Remove the following components: the lower shield, the middle shield, the fan shield and the bottom cabinet frame rail.

10. Remove the middle fan to gain access to the metal cover over the top flywheel upper bearing.

11. Remove the metal shield between the 2 flywheels to gain access to the upper bearing on the lower flywheel and the lower bearing on the upper flywheel.

Lower Bearing Cartridge Remove and Install

Note: Before you begin, the flywheel cabinet must be offline, de-energized, and the flywheel at zero RPM. Have the appropriate replacement parts and tools at hand to perform the bearing change.

Required Tools

Table 1

Description
Drop light
Inspection mirror
5/16-inch Allen wrench
1/4-inch Allen wrench
Socket wrench
9/16-inch socket
1-inch socket
1 1/8-inch socket
1/2-inch socket
11/16-inch open end wrench
1 1/2-inch open end wrench
9/16-inch open end wrench
1 1/16-inch open end wrench
1 1/8-inch open end wrench
Torque wrench
Feeler gauges (4)
190-8385 Bearing Puller Gp
191-5217 Guide Pins
190-8379 Bearing Installer Gp
Vernier caliper
Loctite 262
Electro-Static Discharge (ESD) wrist static strap
Small cross tip screwdriver
High Vacuum Grease

Removal Procedure

Illustration 2	g01953658
(24) Shim Pack (25) O-ring (28) Lower Bearing Cartridge (29) Bolt for Lower Bearing (30) Rotor Retainer (31) Retaining Bolt for Rotor (32) Mounting Bolt for Load Plate (33) Mounting Bolt for Static Drain (34) Mounting Washer for Static Drain (35) Static Drain (36) Load Plate (37) Load Cell (38) Bolt for Load Cell

1. Disconnect the yellow connector for the thermistor and the nineteen pin instrument connector.

2. Remove the four Static Drain screws. Remove the Static Drain.

   Refer to Illustration 2.

3. Remove the Polished Retaining Bolt (20) for the Rotor.

   Refer to Illustration 2.

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Illustration 3	g00712417
190-8386 Shims in place (cutaway view)

4. Remove three SAE plugs from the lower end plate.

5. Install three 190-8386 Shims . Install one tool in each hole. The holes are located in lower housing. Do not remove the Vacuum Hose from the lower housing.

   Note: Refer to Illustration 3 for the correct placement of the 190-8386 Shims . The shims prevent the rotor from setting down on the hall effect sensors.

6. Loosen eight perimeter screws. Use quarter turns. Use a star pattern. Loosen the screws until the rotor rests on the 190-8386 Shims . When the rotor is sitting on the 190-8386 Shims , remove all eight screws.

7. Install a 191-5217 Guide Pin in one of the eight bolt holes that are located in the bearing cartridge. This will prevent the bearing cartridge from turning.

8. Install the 190-8385 Bearing Puller Gp on the bearing cartridge.

9. Turn center bolt (20) clockwise until the bolt contacts the bearing shaft.

   Note: When the bearing is clear of the bearing shaft, the bearing cartridge may fall. Maintain one hand on the bearing cartridge.

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Illustration 4	g01953334

10. Turn center bolt (20) in order to remove the bearing cartridge (22),

    Refer to Illustration 13.

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Illustration 5	g01959437
(22) Bearing Cartridge (23) O-ring (24) Brass Shim

11. Remove O-ring (23) from the bearing cartridge.

12. Remove brass shim (25) from bearing cartridge (22) .

13. Measure the old brass shim and record the measurement. Each bearing cartridge has a unique shoulder height. The height is stamped on the cartridge. The shims are added or removed in order to adjust the height of the shoulder.

14. Record the height of the shoulder.
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    Table 2

    Bearing Measurements
    Old Brass Shim Thickness
    Old shoulder height

    Note: Save and measure the brass shims. The shims may be used during the installation procedure.

Installation Procedure

Illustration 6	g01953658
(24) Shim Pack (25) O-ring (28) Lower Bearing Cartridge (29) Bolt for Lower Bearing (30) Rotor Retainer (31) Retaining Bolt for Rotor (32) Mounting Bolt for Load Plate (33) Mounting Bolt for Static Drain (34) Mounting Washer for Static Drain (35) Static Drain (36) Load Plate (37) Load Cell (38) Bolt for Load Cell

Table 3

Required Tools
Tool	Part Number	Part Description	Quantity
A	191-5217	Guide Pin	2
B	190-8379	Bearing Installer Gp	1
C	7M-7456	Bearing Mount Compound	1
D	190-8380	Spare Shim Kit (1)	1
E	6V-2055	High Vacuum Grease	1

Table 4

Bearing Kit
Part Number	Description	Size	Quantity
190-8380	Shim Kit	0.05 mm	8
190-8382	Shim	0.13 mm	4
190-8383	Shim	0.25 mm	2
190-8384	Shim	0.50 mm	1

Each bearing cartridge has a unique shoulder height. The height is stamped on the cartridge. Shims are added or removed in order to adjust the height of the shoulder.

1. Compare the shoulder height of the old bearing cartridge and the shoulder height of the new bearing cartridge. When brass shims are needed, add brass shims or subtract brass shims. The tolerance of the measurement is ± 0.0508 mm (± 0.002 inch).

   Note: The shoulder height is stamped on the shoulder.

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   Table 5

   Bearing Measurements
   Old Brass Shim Thickness
   Old shoulder height (1)
   New shoulder height (1)
   New Brass Shim Thickness
   Gap between bearing and retainer

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Illustration 7	g01935044
(38) Bolt for Load Cell

2. Install another 191-5217 Guide Pin in one of the eight bolt holes that are located in bearing cartridge (28). This pin should be installed 180 degree away from the first pin. This will locate the bearing cartridge during installation.

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Illustration 8	g01959437
(22) Bearing Cartridge (23) O-ring (24) Brass Shim

3. Align the Amphenol connector for the thermistor so that the harness cable will reach the connector, from the Flywheel Interface Board.

4. Install the new bearing cartridge.

   Use your hand and seat the bearing cartridge.

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Illustration 9	g01953286
190-8379 Bearing Installer Gp (40) Nut (41) Center Bolt

5. Install 190-8379 Bearing Installer Gp on the lower bearing housing.

6. Turn center bolt (26) clockwise until snug.

7. Using an 11/16-inch open-end wrench, tighten the outer nut with a 1 1/2-inch open end wrench until the bearing seats completely on the rotor journal.

8. Insert and start threading two 5/16-inch socket cap bolts in opposing bearing bolt holes. They should be threaded loosely.

9. Remove the 2 guide pins.

10. Remove the 190-8379 Bearing Installer Gp from the rotor journal.

11. Tighten the socket cap bolts to 27 N·m (20 lb ft).

12. Clean the bottom retainer bolt threads.

    Note: If the bolt head shows wear, replace the bolt. A smooth surface is very important for proper operation.

Flywheel Interface Board and Cable Removal

Illustration 10	g01953684

1. Disconnect the 24 V power cable at "J1".

2. Disconnect the APC ribbon cable at "J3".

3. Disconnect the APC ribbon cable at "J2".

4. Disconnect the vacuum sensor cable at "J10".

5. Disconnect the top bearing thermistor cable at "J7".

6. Disconnect the top flywheel harness at "J5".

7. Disconnect the Comm/Accel ribbon cable at "J27".

8. Disconnect the bottom bearing thermistor cable at "J6".

9. Disconnect the bottom flywheel harness at "J4".

10. Remove yellow thermistor cables at the top and bottom of the flywheel. Set the cables aside.

11. Remove top and bottom harnesses from the flywheel. Set the harnesses aside.

12. Remove the three mounting screws on the flywheel interface board. Remove the board.

Upper Bearing Cartridge Remove and Install

Removal Procedure

Illustration 11	g01953573
Upper Bearing Assembly (17) Screw for Position Sensor (18) Rotor Position Sensor (19) O-ring for Rotor Position Sensor (20) Retaining Bolt for Rotor (21) Rotor Wheel (22) Bearing Bolt (23) Upper Bearing Cartridge (24) Shim Pack (25) O-ring

1. Remove three screws for the Rotor Position Sensor (18) .

2. Remove the Rotor Position Sensor assembly.

3. Remove the O-ring (19) for the Rotor Position Sensor (18) .

4. Remove the Retaining Bolt (20) for the Rotor.

5. Remove Rotor Wheel (21) .

6. Loosen eight perimeter Allen screws.

   Note: Use quarter turns in a star pattern.

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Illustration 12	g01927614
Location of Guide Pin

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Illustration 13	g01953334

7. Install one 191-5217 Guide Pin in one of the eight bolt holes that are located in the bearing cartridge,

   Installing the 191-5217 Guide Pin will prevent the bearing cartridge from turning. Do not use the 2 holes outward from the Bearing Puller Group Mounting. This will prevent the Bearing Puller tool from properly attaching to the bearing.

8. Install the 190-8385 Bearing Puller Gp on the bearing cartridge.

9. Turn center bolt (20) clockwise until the bolt contacts the bearing shaft, refer to.

10. Turn center bolt (20) in order to remove the bearing cartridge.

11. Remove Black O-ring from the bearing cartridge.

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Illustration 14	g01810454

12. Remove Brass Shim Pack from upper bearing housing.

    Note: Ensure the old brass shim and record the measurement. Each bearing cartridge has a unique shoulder height. The height is stamped on the cartridge. The shims are added or removed in order to adjust the height of the shoulder. Save the brass shim. The shim may be used during the installation procedure.

13. Record the height of the shoulder using Table 6.
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    Table 6

    Bearing Measurements
    Old Brass Shim Thickness
    Old shoulder height
    New shoulder height
    New Brass Shim Thickness

Installation Procedure

Illustration 15	g01953573
Upper Bearing Assembly (17) Screw for Position Sensor (18) Rotor Position Sensor (19) O-ring for Rotor Position Sensor (20) Retaining Bolt for Rotor (21) Rotor Wheel (22) Bearing Bolt (23) Upper Bearing Cartridge (24) Shim Pack (25) O-ring

Table 7

Required Tools
Tool	Part Number	Part Description	Quantity
A	191-5217	Guide Pin	2
B	190-8379	Bearing Installer Gp	1
C	7M-7456	Bearing Mount Compound	1
D	190-8380	Shim Kit	1
E	6V-2055	Grease	1

Table 8

Bearing Kit
Part Number	Description	Size	Quantity
190-8380	Shim Kit	0.05 mm	8
190-8382	Shim	0.13 mm	4
190-8383	Shim	0.25 mm	2
190-8384	Shim	0.50 mm	1

Each bearing cartridge has a unique shoulder height. The height is stamped on the cartridge. Shims are added or removed in order to adjust the height of the shoulder.

1. Compare the shoulder height of the old bearing cartridge and the shoulder height of the new bearing cartridge. When brass shims are needed, add brass shims or subtract brass shims. The tolerance of the measurement is ± 0.0508 mm (± 0.002 inch).

   Note: The shoulder height is stamped on the surface of the Bearing Cartridge.

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Illustration 16	g01949404
(23) Upper Bearing Cartridge (24) Shim Pack (25) O-ring

2. Install another 191-5217 Guide Pin in one of the six bolt holes that are located in bearing cartridge (22) .

   This pin should be installed 180 degrees away from the first pin. This will locate the bearing cartridge during installation.

3. Align the 6 pin Amphenol connector to enable it to reach the connecting harness from the PWI board.

4. Install the new bearing cartridge.

   Use your hand and seat the bearing cartridge.

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Illustration 17	g01949406
190-8379 Bearing Installer Gp (25) Nut (26) Center Bolt

5. Install 190-8379 Bearing Installer Gp on the upper bearing housing.

6. Turn center bolt (26) clockwise until snug.

7. Turn nut (25). Seat the bearing cartridge.

8. Remove the 190-8379 Bearing Installer Gp from the rotor journal.

9. Remove the 2 Guide Pins.

10. Install six perimeter screws. Use quarter turns. Tighten the screws in a star pattern. Tighten the screws until the rotor does not rest on the Shim. Tighten the screws to 27 N·m (20 lb ft).

11. Clean the threads on the Rotor Retainer Bolt with a wire brush or replace the bolt.

12. Place one drop 7M-7456 Bearing Mount Compound on the threads of the Rotor Retainer Bolt.

13. Install Rotor Wheel (21) and Retaining Bolt (20) for the Rotor.

14. Tighten the Retaining Bolt (20) for the Rotor to 38 N·m (28 lb ft).

    Note: Do not reinstall the Rotor Position Sensor (18) at this time. It should be reinstalled after the lower Bearing cartridge and Load Cell have been installed.

15. Continue with the procedure for lower bearing removal and installation.

Flywheel Interface Board and Cable Installation

Illustration 18	g01953718

1. Attach the new board to the chassis using the uppermost mounting hole.

2. Tighten all screws to secure the board into place.

3. Connect the +24VDC control power at "J1".

4. Connect the "APC_FW_TOP" connector at "J2".

5. Connect the "APC_FW_BOTTOM" connector at "J3".

6. Connect the "FW BOTTOM 1" connector at "J4".

7. Connect the "FW TOP" connector at "J5".

8. Connect the "FW BOTTOM 2" connector at "J6".

9. Connect the "COMM/ACCEL" connector at "J9".

10. Connect the RJ-45 Vacuum Sensor connector at "J10".

Continuity Check

After the charge drain and the load cell is installed, check for continuity using the following procedure:

1. The commutation sensor should still be disassembled from the flywheel. If the commutation sensor is not removed, remove the commutation sensor.

2. With a standard ohmmeter, check continuity between the retaining bolt of the upper rotor and any unpainted, bare metal surface on the flywheel housing.

   If there is no continuity, the charge drain has not been installed and adjusted properly.

3. If continuity does not exist:
   • Remove the load cell from the lower bearing cartridge.

   • Check the installation of the charge drain and the height adjustment.

   • Verify that the contact surfaces are clean.

   • Check continuity between the upper retaining bolts for the rotor and the lower retaining bolts for the rotor.

   • Reinstall the load cell.

   • Repeat the check for continuity.

4. Once continuity is verified, reinstall the commutation sensor onto the upper bearing cartridge.

5. Apply a light coat of vacuum grease to the commutation sensor O-ring. Reinstall the commutation sensor onto the assembly in the O-ring groove.

6. Reinstall the commutation sensor with the three mounting screws.

7. Remove the support shims for the rotor.

   If the support shims for the rotor are still bound between the rotor and pole ring surface, remove the "load cell" and add a "2 mil" shim to the shim package for the load cell. Reinstall the "load cell".

   Note: If the shim package for the bearing cartridge is measured correctly, then no more than one shim should be required in this adjustment. If the gap between the retainer and bearing is less than "6 mils", the cartridge must be removed and an additional "2 mil" shim must be added to the brass shim package:

   • If the gap is "7 mils", one "2 mil" shim may be added to the shim package for the load cell.

   • If the gap is "9 mils", two "2 mil" shims may be added to the "Load Cell" shim package.

   If the load plate is stuck, try to wiggle the load plate by hand. Do not use a screwdriver or any other tool because of the risk of damaging the charge drain.

8. Apply Dow-Corning high vacuum grease to the O-rings that are located on four plugs.

9. Install the three plugs.

10. Connect the lower harness from the Flywheel Interface Board to the load cell connector.

11. Connect the lower harness from the Flywheel Interface Board to the lower flywheel housing connector.

12. Connect the upper harness from the Flywheel Interface Board to the upper bearing cartridge connector.

13. Connect the upper harness from the Flywheel Interface Board to the upper flywheel housing.

14. The hall probe to G3.5 load cell conversion is complete.

15. Refer to the ""Bearings Change Post-Removal Steps" ".

Bearings Change Post-Removal Steps

1. Replace the metal shield over the upper bearing for the flywheel.

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Illustration 19	g01271376
Reattach the lower rail bolt. (21) Bolt (49) Lower Frame Rail

2. Replace the frame rail (49) of the bottom cabinet.

   Only four bolts need to be reattached. Refer to Illustration 19.

3. Close and lock the doors of the cabinet by using a hex key on the upper and lower latches.

4. With UPSView, update the installation date of the bearings in the UPS firmware for each flywheel bearing that was replaced.

   "Op. Params > Op. Group 8: > Bearing Install Day"

   "Op. Params > Op. Group 8: > Bearing Install Month"

   "Op. Params > Op. Group 8: > Bearing Install Year"

5. Put the UPS into on-line Mode via UPSView.

6. Enter the value for the "Load Cell Offset" in the "Op. Params > Op. Group 7: > Load Cell Offset" menu in UPSView.

7. Enter the value for the "Load Cell Calibration Factor" into the "Op. Params > Op. Group 7: > Load Cell Cal. Factor" menu in UPSView.

8. Enter the value for the "Load Cell Serial Number" into the "Op. Params > Op. Group 13: > Load Cell Serial Num." menu in UPSView.

9. Calibrate the "Vibration Sensor Zeroes" in accordance with the calibration procedure Systems Operation, Testing and Adjusting, RENR9988, "Vibration Sensors Calibration".

   Note: This calibration pertains only to firmware prior to 3.22.

10. Calibrate RPS Advance setpoint. Use the procedure Systems Operation, Testing and Adjusting, RENR9988, "RPS Advance Setpoint Calibration".

11. Turn the keyswitch of the MMU cabinet to the on-line position.

    The change for the bearing is complete.