UPS 1000S/ UPS 1200S Uninterruptible Power Supplys Caterpillar

Description

Illustration 1	g01285975
Location of the Flywheel Inverter Assembly (1) Flywheel Inverter Assembly

The Flywheel Inverter assembly is located in the upper right side of the flywheel cabinet. When online, the Flywheel Inverter is used to convert the DC voltage to AC Voltage in order to keep the flywheel at speed. During discharge, the Flywheel Inverter assembly converts the 3-phase AC voltage from the flywheels in order to keep the DC Bus charged. The regulated DC voltage is used by the Inverter Cabinet where the energy is converted back to AC voltage to supply the customer load.

Each cabinet for the flywheel contains two inverter assemblies. Each Inverter assembly is made up of three Inverter modules. Each complete Inverter assembly includes the following components:

• Flywheel Inverter module

• DC capacitors

• heat sink

Illustration 2 shows a complete Flywheel Inverter module.

Illustration 2	g01286018
Complete Flywheel Inverter Module (2) DC Bus Connector (3) Ribbon Connector to SKI PWA J1 (4) Inverter Module (5) Inverter Module Bus Connections (6) Heat Sink (7) Shroud (8) DC Capacitors

Illustration 3	g01286610
Flywheel Inverter Assembly

Removal Procedure

Refer to Systems Operation, Testing and Adjusting, RENR7654, "Internal Component Preremoval Steps (Flywheel Cabinet)" in order to shut down the system and gain access to internal components.

Illustration 4	g01286105
SKiiP Interface Board

1. Remove the tie wraps that hold the three SKiip Interface (SKI) wire toroids away from the bus work.

2. Disconnect the three connectors from each of the three SKI boards. Verify the labeling on each connector with the location of all connectors. Refer to Illustration 4.

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Illustration 5	g01286128
Inverter A (9) Fuse Switch Indicators for Inverter A

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Illustration 6	g01286149
Inverter B (10) Fuse Switch Indicators for Inverter B

3. Disconnect the wiring for the fuses from Inverter A (9). The wires run from the Field Coil Driver boards to the Field Coil Driver fuses.

   Refer to Systems Operation, Testing and Adjusting, RENR7654, "Field Coil Driver" for the location of the Field Coil Driver boards.

4. Disconnect the two wires from each of the Fuse Status Indicators on the front of each bus fuse for the Inverter to be removed. Refer to Illustration 5 for Inverter A (9) removal and Illustration 6 for Inverter B (10) removal.

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Illustration 7	g01286157
Inverter A (11) Wire and Cable Connections for Inverter A

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Illustration 8	g01286158
Inverter B (12) Wire and Cable Connections for Inverter B

5. Disconnect the wires and cables that connect to the front bus work on the Inverter that is to be removed. Refer to Illustration 7 for inverter A (11) and Illustration 6 for Inverter B (12) .

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Illustration 9	g01286210
(13) A and B Inverter Bus Work Connection Bolt

6. Remove the Inverter bus work connection bolt (13). Refer to Illustration 9.

7. Remove the ribbon cable from the top left side of the Inverter module. Refer to Illustration 4.

8. Remove the DC Bus cable located on the top left side of the Inverter module. Refer to Illustration 2.

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Illustration 10	g01286463
Inverter Module Connection

9. Remove the six bolts that hold the bus work of the Inverter modules. Refer to Illustration 10.

10. Remove the four bolts that hold the Inverter module to the ceiling panel of the cabinet.

11. Remove the Inverter module straight out the front of the cabinet.

12. Follow Steps 7 through 11 to remove each additional Inverter module that is located in the bank.

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Illustration 11	g01286487
3-SKI Board Mounting Frame (14) Screws

13. When replacing Inverter module A (9), remove the three screws from the side of the 3-SKI Board mounting frame.

14. Remove the 3-SKI board assembly from the front of the Flywheel Inverter assembly.

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Illustration 12	g01286526
Inverter A (15) Bolts for the Front Bus Work

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Illustration 13	g01286536
Inverter B (16) Bolts for the Front Bus Work

15. Remove the bolts that hold the fuses and bus work to the Inverter module A (9). Refer to Illustration 12 for Inverter A. Refer to Illustration 13 for Inverter B.

Installation Procedure

1. To install Inverter module A (9), Install the Flywheel Inverter front fuses and bus work to the Inverter module. Refer to Illustration 12 for Inverter A. Refer to Illustration 13 for Inverter B.

2. Tighten the bus work bolts to 11.3 N·m (100 lb in).

3. To install Inverter module A (9), Install the 3-SKI board mounting frame to the front Inverter module with the three screws (14) .

4. Position the Inverter module onto the ceiling panel rail from the front.

5. Install the inverter module bus work with the six bolts to the Inverter module located behind it.

6. Install the Inverter module to the ceiling rail with the four bolts.

7. Tighten the ceiling rail and bus work bolts to 11.3 N·m (100 lb in).

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Illustration 14	g01286579

8. Install the DC Bus cable to the top left side of the Inverter module. Refer to Illustration 2 for cable connections. Refer to Illustration 14 for hardware connections.

9. Tighten the DC Bus cable to 9 N·m (80 lb in).

10. Install the ribbon cable to the top left side of the Inverter module Refer to Illustration 2.

11. Perform Steps 1 through 9 for each Inverter module in the bank.

12. Install all cables and wires to the bus work and fuses. Refer to Illustration 7for Inverter A. Refer to Illustration 8 for Inverter B.

13. Install the wires from the Field Coil Drivers board to the bus fuses.

14. Tighten the fuse bolts to 13.5 N·m (120 lb in).

15. Install the two wires to each of the Fuse Status Indicators on the front of each bus fuse. Refer to Illustration 5 for Inverter A (9). Refer to Illustration 6 for Inverter B (10) .

16. Install the metal shield on Inverter A. Refer to Illustration 3.

17. Install the three connectors to each of the three SKI boards. The connectors locations in the unit are labeled. Refer to Illustration 4.

18. Install tie warps on the toroids.

    Note: Install toroids away from the bus bars so that no contact is possible.