UPS 750 Uninterruptible Power Supply Caterpillar

Power Distribution for DC Voltage (PDDC)

Illustration 1	g03687112
Power distribution DC board (PDDC) location - right side cabinet view

Illustration 2	g03687117
PDDC board

The power distribution DC board is located in the right panel of the SIO cabinet. Within the SIO cabinet, the power distribution DC board is on the right side of the main static switch air duct. PDDC receives 24 VDC input power from PS1 and PS2. The PDDC then supplies all 24 VDC power to satellite boards in the unit. The PDDC also contains isolation fuses for the satellite boards.

Removal

1. Refer to Systems Operation, Test and Adjust, UENR4695, "Internal Component Pre-Removal Steps". Perform the internal component pre-removal procedure to shut down the system and to gain access to internal components.

2. Disconnect all 24 V connectors. The connectors are labeled to identify the correct location for each connector. Verify each connector label.

3. Disconnect the six white plastic stand-offs connecting the board to the left panel using the following method.

   Note: The board must be removed from the stand-offs without bending the board.

   1. Pinch the head of each stand-off so that the board is not locked but is still attached to the stand-off.

   2. Remove the board by gently and evenly pulling the board from all stand-offs at the same time.

Installation

1. Position the board in the cabinet over the nine white stand-offs that are connected to the left panel.

2. Push the board, gently and evenly, onto all the stand-offs simultaneously. Make sure all the stand-offs are locked in place.

3. Plug the wire connectors into the correct connectors on the board. Check the labels on each connector to ensure proper installation.

Power Distribution for AC Voltage (PDAC)

Illustration 3	g03687434
Location of board for power distribution for AC voltage (PDAC) (4) PDAC board

Illustration 4	g03687435
PWA power distribution AC board (PDAC)

The PDAC board is located in the right panel of the SIO cabinet. PDAC receives 230 VAC and 160 VAC from transformers T1, T2, and T3. PDAC distributes the AC power for operation of contactors K1, K2, K3 and K4, the vacuum pump, and power supplies PS1 and PS2. The PDAC also contains isolation fuses for all loads supplied.

Removal

1. Refer to Systems Operation, Test and Adjust, UENR4695, "Internal Component Pre-Removal Steps". Perform the internal component pre-removal procedure to shut down the system and to gain access to internal components.

2. Disconnect all connectors. The connectors are labeled to identify the correct location for each connector. Verify each connector label.

3. Disconnect the eight white plastic stand-offs that connect the board to the left panel. Use the following method.

   Note: The board must be removed from the stand-offs without bending the board.

   1. Pinch the head of each stand-off so that the board is not locked but is still attached to the stand-off.

   2. Remove the board by gently and evenly pulling the board from all stand-offs at the same time.

Installation

1. Position the board in the cabinet over the eight white stand-offs that are connected to the left panel.

2. Push the board, gently and evenly, onto all the stand-offs simultaneously. Make sure all stand-offs are locked in place.

3. Plug the wire connectors into the correct connectors on the board. Check the labels on each connector to ensure proper installation.

4. Calibrate the PWA. Refer to the next section for calibrations.

Calibrations

The following calibrations must be performed:

• AC system currents

• AC system voltages

Flywheel Current (Excitation Field Coil Current)

1. Verify that the flywheel is at 0 rpm.

2. Verify that the UPS is in "Bypass" mode.

3. Enter engineering level password.

4. Under the "Calibrate" menu, select "CALIBRATION GROUP 2: FLYWHEEL CURRENT: EXCITATION FIELD COIL CURRENT".

5. Calibrate excitation field coil current opens.

6. Press "Ctrl" + "I" to auto start the inverters on.

7. Press "Ctrl" + "M" to place the UPS in "Manual" mode.

Input/Output/Filter AC Voltages

1. Verify that the UPS is in "Bypass" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 3: INPUT/OUTPUT/FILTER AC VOLTAGES: INPUT VAC AB". The "Calibrate Input VAC AB" window opens.

4. Measure input voltage phase A to B in the SIO cabinet with voltmeter.

5. Adjust "Fast/Slow Gain" to change "New: Value" to match voltmeter.

6. Save new value.

7. Close the "Calibrate Input VAC AB" window.

1. Verify that the UPS is in "Bypass" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 3: INPUT/OUTPUT/FILTER AC VOLTAGES: INPUT VAC BC". The "Calibrate Input VAC BC" window opens.

4. Measure input voltage phase B to C in the SIO cabinet with voltmeter.

5. Adjust "Fast/Slow Gain" to change "New:Value" to match the voltmeter.

6. Save the new value.

7. Close the "Calibrate Input VAC BC" window.

1. Verity that the UPS is in "Bypass" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 3: INPUT/OUTPUT/FILTER AC VOLTAGES: INPUT VAC BN". The "Calibrate Input VAC BN" window opens.

4. Measure input voltage phase B to N in the SIO cabinet with voltmeter.

5. Adjust "Fast/Slow Gain" to change "New:Value" to match voltmeter.

6. Save the new value.

7. Close the "Calibrate Input VAC BN" window.

1. Verify that the UPS is in "Bypass" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 3: INPUT/OUTPUT/FILTER AC VOLTAGES: OUTPUT VAC AB". The "Calibrate Output VAC AB" window opens.

4. Measure the output voltage phase A to B in the SIO cabinet with voltmeter.

5. Adjust "Fast/Slow Gain" to change "New:Value" to match the voltmeter.

6. Save the new value.

7. Close the "Calibrate Output VAC AB" window.

1. Verify that the UPS is in "Bypass" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 3: INPUT/OUTPUT/FILTER AC VOLTAGES: INPUT VAC BC". The "Calibrate Output VAC BC" window opens.

4. Measure input voltage phase B to C in the SIO cabinet with voltmeter.

5. Adjust "Fast/Slow Gain" to change "New:Value" to match voltmeter.

6. Save the new value.

7. Close the "Calibrate Output VAC BC" window.

1. Verify that the UPS is in "Bypass" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 3: INPUT/OUTPUT/FILTER AC VOLTAGES; OUTPUT VAC BN". The "Calibrate Output VAC BN" window opens.

4. Measure input voltage phase B to N in the SIO cabinet with a voltmeter.

5. Adjust "Fast/Slow Gain" to change "New: Value" to match voltmeter.

6. Save the new value.

7. Close the "Calibrate Input VAC BN" window.

1. Verify that the UPS is in "Bypass" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 3: INPUT/OUTPUT/FILTER AC VOLTAGES: INPUT VAC AB". The "Calibrate Input VAC AB" window opens.

4. Press "Ctrl" + "I" to turn on inverters.

5. Measure input voltage phase A to B in the SIO cabinet with a voltmeter.

6. Adjust "Fast/Slow Gain" to change "New:Value" to match voltmeter.

7. Save new value.

8. Close the "Calibrate Input VAC AB"window.

9. Use "Ctrl" + "M"to place the UPS in "Manual" mode.

10. Press "Ctrl" + "B" to return the UPS to "Bypass" mode.

1. Verify that the UPS is in "Bypass" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 3: INPUT/OUTPUT/FILTER AC VOLTAGES: INPUT VAC BC". The "Calibrate Input VAC BC" window opens.

4. Use "Ctrl" + "I" to turn on the inverters.

5. Measure Input voltage phase B to C in the SIO cabinet with voltmeter.

6. Adjust "Fast/Slow Gain" to change "New: Value" to match voltmeter.

7. Save the new value.

8. Close the "Calibrate Input VAC BC" window.

9. Use "Ctrl" + "M" to place the UPS in "Manual" mode.

10. Use "Ctrl" + "B" to return the UPS to "Bypass" mode.

1. Verify that the UPS is in "Bypass" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 3: INPUT/OUTPUT/FILTER AC VOLTAGES: INPUT VAC BN". The "Calibrate Input VAC BN" window opens.

4. Use "Ctrl" + "I" to turn on inverters.

5. Measure input voltage phase B to N in the ISO cabinet with voltmeter.

6. Adjust "Fast/Slow Gain" to change "New: Value" to match voltmeter.

7. Save new value.

8. Close the "Calibrate Input VAC BN" window.

9. Use "Ctrl" + "M" to place the UPS in "Manual" mode.

10. Use "Ctrl" + "B" to return the UPS to "Bypass" mode.

AC Currents

1. Verify that the UPS is in "Online" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 6: AC CURRENTS: INPUT CURRENT A". The "Calibrate Input Current A" window opens.

4. Measure input current phase A in the SIO cabinet with amperage meter.

5. Adjust "Fast/Slow Gain" to change "New: Value" to match amperage meter.

6. Save new values.

7. Close the "Calibrate Input Current A" window.

1. Verify that the UPS is in "Online" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 6: AC CURRENTS: INPUT CURRENT B". The "Calibrate Input Current B" window opens.

4. Measure input current phase B in the SIO cabinet with amperage meter.

5. Adjust "Fast/Slow Gain" to change "New: Value" to match amperage meter.

6. Save the new value.

7. Close the "Calibrate Input Current A" window.

1. Verify that the UPS is in "Online" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 6: AC CURRENTS; INPUT CURRENT C". The "Calibrate Input Current C" window.

4. Measure input current phase C in the SIO cabinet with amperage meter.

5. Adjust "Fast/Slow Gain" to change "New: Value" to match amperage meter.

6. Save the new value.

7. Close the "Calibrate Input Current C" window.

1. Verify that the UPS is in "Online" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 6: AC CURRENTS: OUTPUT CURRENT A". The "Calibrate Output Current A" window opens.

4. Measure output current phase A in the SIO cabinet with the amperage meter.

5. Adjust "Fast/Slow Gain" to change "New: Value" to match amperage meter.

6. Save new value.

7. Close the "Calibrate Output Current A" window.

1. Verify that the UPS is in "Online" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 6: AC CURRENTS: OUTPUT CURRENT B". The "Calibrate Output Current B" window opens.

4. Measure output current phase B in the SIO cabinet with amperage meter.

5. Adjust "Fast/Slow Gain" to change "New: Value" to match amperage meter.

6. Save the new value.

7. Close the "Calibrate Output Current B" window.

1. Verify that the UPS is in "Online" mode.

2. Enter the engineering level password.

3. Under the "Calibrate" menu, select "CALIBRATION GROUP 6: AC CURRENTS: OUTPUT CURRENT C". The "Calibrate Output Current C" window opens.

4. Measure output current phase C in the SIO cabinet with amperage meter.

5. Adjust "Fast/Slow Gain" to change "New: Value" to match amperage meter.

6. Save the new value.

7. Close the "Calibrate Output Current C" window.