- Uninterruptible Pwr Su
- UPS 1000S (S/N: CZS1-UP)
- UPS 1000Z (S/N: EDZ1-UP)
- UPS 120 (S/N: CNK1-UP)
- UPS 1200S (S/N: CZT1-UP)
- UPS 1200Z (S/N: HDR1-UP)
- UPS 150 (S/N: CPC1-UP)
- UPS 250 (S/N: BEE1-UP; CNM1-UP; APZ1-UP)
- UPS 300 (S/N: CNJ1-UP; CPZ1-UP)
- UPS 301 (S/N: CSY1-UP)
- UPS 500 (S/N: CSE1-UP)
- UPS 600 (S/N: CTX1-UP)
- UPS 750 (S/N: AD21-UP; CD71-UP; CPM1-UP)
- UPS 900 (S/N: CRY1-UP)
- UPS500G (S/N: TYD1-UP)
- UPS600G (S/N: DLD1-UP)
- UPS 1000Z (S/N: EDZ1-UP)
Introduction
This Special Instructions outlines the restoration procedure for flywheel lockout. Flywheel lockout will cause the Uninterrupted Power Supply (UPS) to brake the flywheel to 20 RPM and lock it out. Lockout will prevent UPS from being returned to online. A locked out flywheel can only be restarted by changing the bearing installation date.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Reference Section
Reference: Refer to System Operation, Testing and Adjusting, RENR9988, "UPS 120, UPS 150, UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750, and UPS 900 Uninterrupted Power Supplies".
Reference: Refer to Flywheel Start-up Checklist Manual, LEXE0405-02, "Flywheel UPS 300 series Start Up Checklist" on Power Net at https://powernet-legacy.cat.com for additional information.
Important Safety Information
Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.
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 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. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.
Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.
After power is removed, wait for 5 minutes before the UPS is opened. This action allows the capacitors to discharge. Ensure that the capacitors are at a zero energy level before performing work.
Personal Protective Equipment (PPE) suitable to the work being performed must be worn when performing maintenance on the UPS.
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Personal injury or death can result from lifting, moving, and lowering heavy assemblies. A heavy assembly can slip and fall off the forks of the fork lift if the assembly is not properly balanced and secured onto the forks of the fork lift . Be sure that the assembly is properly balanced and secured on the forks of the fork lift. Be sure that the fork lift has the correct capacity to lift the stated weight of the assembly. For reference, the correct weight of the assembly is listed elsewhere within this document information. |
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Working with electrical circuits is hazardous and exposes personnel to electrical potential. To ensure safe operation, personnel must be trained in proper operating procedures. Bodily contact with electrical potential will cause serious personal injury or death. |
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Power source must be disconnected before working on equipment. Failure to disconnect power source could result in injury or death. |
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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures. |
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Personal injury or death can result from high voltage. Moisture can create paths of electrical conductivity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls "DO NOT OPERATE". |
General Hazard Information
Attach a "Do Not Operate" warning tag or a similar warning tag to the key switch or to the controls before the system is serviced or before the system is repaired. These warning tags are available from your Caterpillar dealer. Attach the warning tags to the system and to each operator control station.
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| Illustration 1 | g00104545 |
Reason for a Flywheel Lockout
The reasons for a flywheel lockout are listed below:
- High vibration (0.8G) for 30 seconds or more.
- High bearing temperature (
115° C (239° F) ) for 30 seconds or more. - Startup procedure has not been completed on UPS.
SMS - Online Mode
The following are the flywheel lockout sequences when the UPS is in SMS online mode:
- If the UPS is in online mode when a high bearing temperature or vibration error occurs, system will enter into the Automatic Voltage Regulation (AVR) mode and begin braking mode.
- Flywheel braking will continue until the flywheel reaches 20 RPM or for a maximum of 20 minutes.
- Once the flywheel shutdown (braking) operation is complete (20 RPM or 20 minutes), the system will stay in AVR mode with the flywheel locked-out.
SMS - Discharge Mode
The following are the flywheel lockout sequences when the UPS is in SMS discharge mode:
- If the UPS is in discharge when a high bearing temperature or vibration error occurs, system will enter into the AVR mode and begin braking mode after the discharge has ended.
- Flywheel braking will continue until the flywheel reaches 20 RPM or for a maximum of 20 minutes.
- Once the flywheel shutdown (braking) operation is complete (20 RPM or 20 minutes), the system will stay in AVR mode with the flywheel locked-out.
SMS - Bypass Mode
The following are the flywheel lockout sequences when the UPS is in SMS bypass mode:
- If the UPS is in the flywheel shutdown (braking) mode and moves to bypass mode, the braking will be stopped.
- If the UPS returns back to AVR mode (online key-switch), system will continue braking the flywheel until it reaches 20 RPM or for a maximum of 20 minutes.
- If the UPS is in bypass mode and a high bearing temperature or vibration error occurs, no action will be taken but the flywheel will be locked out.
- If the UPS returns back to AVR mode (online key-switch), system will begin braking the flywheel until it reaches 20 RPM or for a maximum of 20 minutes.
MMS - Online Mode
The following are the flywheel lockout sequence when the UPS is in MMS online mode:
- If the UPS is in online mode when a high bearing temperature or vibration error occurs, the affected flywheel will enter into the Automatic Voltage Regulation (AVR) mode and begin braking mode as long as the remaining flywheels are able to assume the load. If remaining flywheels are not capable of assuming the load, UPS will enter into the AVR mode.
- Flywheel braking will continue until the flywheel reaches 20 RPM or for a maximum of 20 minutes.
- Once the flywheel shutdown (braking) operation is complete (20 RPM or 20 minutes), the flywheel will be locked-out.
MMS - Discharge Mode
The following are the flywheel lockout sequence when the UPS is in MMS discharge mode:
- If the UPS is in discharge when a high bearing temperature or vibration error occurs, the affected flywheel will enter into the Automatic Voltage Regulation (AVR) mode and begin braking mode after the discharge has ended as long as the remaining flywheels are able to assume the load. If remaining flywheels are not capable of assuming the load, UPS will enter into the AVR mode.
- Flywheel braking will continue until the flywheel reaches 20 RPM or maximum of 20 minutes elapses.
- Once the flywheel shutdown (braking) operation is complete (20 RPM or 20 minutes), the flywheel will be locked-out.
MMS - Bypass Mode
The following are the flywheel lockout sequence when the UPS is in MMS bypass mode:
- If the UPS is in the flywheel shutdown (braking) mode and moves to bypass mode, the braking will be stopped.
- If the UPS returns back to AVR mode (online key-switch), system will continue braking the flywheel until it reaches 20 RPM or the 20 minutes timer expires as long as the remaining flywheels are able to assume the load. If remaining flywheels are not capable of assuming the load, UPS will remain in bypass mode.
- If the UPS is in bypass mode and a high bearing temperature or vibration error occurs, no action will be taken but the flywheel will be locked out.
- If the UPS returns back to AVR mode (online key-switch), system will begin braking the flywheel until it reaches 20 RPM or the 20 minutes timer expires as long as the remaining flywheels are able to assume the load. If remaining flywheels are not capable of assuming the load, UPS will remain in bypass mode.
Restoration from Flywheel Lockout
Note: A locked out flywheel can only be restarted by changing the bearing install date via UPS View.
Perform the following steps to restore the flywheel from lockout:
- Download all error logs, telemeter data (if available), and other information available to determine the cause of the lockout.
- Review installation of UPS against the Start-up checklist requirements to determine if external causes could have caused the lockout.
- Evaluate the data and UPS bearing to determine if the bearing needs to be changed.
- If it is determined the bearing could have been damaged, replace the bearing, otherwise skip this step.
- Perform Rotor Positioning Sensor (RPS) calibration. Refer to the above mentioned System Operation, Testing and Adjusting manual for details on this process.
- Update the bearing install date.
- If a new bearing was installed use the new bearing install date.
- If a new bearing was not required, advance the bearing install date by one day from the previously shown date.
- Monitor and record bearing temperatures and vibration.