UPS 750 Uninterruptible Power Supply System Overview Caterpillar

System Overview
1.1. UPS Cabinets
2.2. System Input/Output (SIO) Cabinet
3.2. Flywheel Cabinet
4.1. Single Input 3-Wire Diagram
5.1. Single Input 4-Wire Diagram
6.1. Control Panel

The CatUninterruptible Power Supply UPS750 is a fully integrated line-interactive system. The system uses a flywheel to store mechanical energy in the form of a rotating mass. When power from the utility is interrupted, the UPS will convert the energy that is stored in the flywheel to electrical energy. This energy is supplied to the external load until one of the following conditions occur:

  • The standby generator assumes the load

  • The utility power is available again

  • The flywheel runs out of energy

Once utility power service returns, the system will transfer the load back to utility power service without an interruption. The UPS can be used in a wide range of commercial power applications. The systems provide voltage regulation and protection from power failures. The system helps provide regulated power to critical loads in the event of sags, surges, or outages.

The following information is to provide an overview of the components for the 60 Hz UPS750 unit. The systems consist of two cabinets.

  • The system input/output (SIO) cabinet

  • The flywheel cabinet (also referred to as the flywheel power unit or FPU)

The nodes determine the state of the system. The input node and the output node are externally available. The nodes are used to attach the system to a power source and to the load. The filter node is used internally by the system. The DC bus is used as a power source for the field coil currents.

Note: The system and Input/output cabinet can be configured for either single or dual input at the factory.

The system cabinets are transported as separate individual units, along with the flywheel module which is separated from the FPU for shipment. The cabinets are assembled as a single system at the installation site. The System input/output cabinet weighs 2109 kg (4650 lb). The flywheel power cabinet weighs 1020 kg (2250 lb), and the flywheel module weighs 2245 kg (4950 lb). Together as a system, the total combined weight of both cabinets is 5375 kg (11850 lb).

UPS Cabinets

System Input/Output (SIO) Cabinet

The SIO cabinet contains the following components:

  • Customer Power Connections

  • Customer Interface (CIO) PWA

  • SIO User Display Interface Panel

  • Emergency Power Off (EPO) Button

  • Bypass Switch

  • Static Bypass Switch

  • Line Static Switch

  • Input and Output Bypass Switches

  • Line and Filter Inductors

  • Main Controller Board

  • Voltage and Current Sensing

Illustration 1g03465485
System input/output (SIO) cabinet
(1) Touch screen interface panel
(2) SIO cabinet doors
(3) Filters (six filters for SIO cabinet doors)

Illustration 2g03788096
Typical example of a three wire system input/output (SIO) cabinet with front doors removed. Inside/front view.
(5) Generator set start module (GSM) breaker
(6) Bypass static switch
(7) K3 contactor
(8) K4 contactor
(9) Bypass static switch snubber board
(10) Bypass static switch driver board
(11) K2 contactor
(12) K1 contactor
(13) APC3 board
(14) Bypass static switch thyristors
(15) CIO board

Illustration 3g03788116
Typical example of the front right corner view of the UPS
(20) VCI-1 Board
(21) Utility bus phase A
(22) Utility bus phase B
(23) Utility bus phase C
(24) Breaker control board
(25) Power distribution DC board
(26) VCI-2 board
(27) VCI-3 board
(28) PS 1 and PS 2 power supplies
(29) Modem

Illustration 4g03788316
Typical example of the front left corner view of the UPS
(35) Power distribution AC board
(36) Electromagnetic interface (EMI), I/O cabinet
(37) Line static switch snubber board
(38) Line static switch driver board
(39) Line static switch thyristors
(40) Surge traps
(41) AC filter capacitor bank
(42) EMI, three-phase GND caps with resistors to purge power
(43) Fuse, semiconductor

Flywheel Cabinet

The flywheel cabinet contains the following components:

  • Utility inverter

  • Flywheel inverters

  • Flywheel energy storage system

  • Vacuum pump

  • Fans

Illustration 5g03465518
Typical example of the flywheel cabinet
(50) Air filters (4 on each door)
(51) Cabinet doors

Illustration 6g03465492
Typical example of the flywheel cabinet with front doors removed
(52) Utility gate driver board
(53) Utility inverter module
(54) Accelerator board
(55) Power distribution block for fans
(56) Input fuses for fans
(57) DC cap module
(58) Flywheel gate driver board
(59) Flywheel interface board
(60) Flywheel assembly
(61) Vacuum pump
(62) Rotor position sensor

Illustration 7g03469424
Typical example of the flywheel cabinet of the front left corner view
(67) Horizontal fan
(68) Fan interface board
(69) Vacuum gauge
(70) Accelerometer
(71) Vertical fans
(72) Flywheel inverter module
(73) Excitation coil driver board
(74) Armature cables

Single Input 3-Wire Diagram

Illustration 8g03462979
Single input 3-wire diagram
Input: 480 VAC, 3 phase, 60 Hz 3 wire and ground is 846 amps alternating current nominal with 1200 amps alternating current maximum
Output: 903 amps alternating current nominal, 3 wire, and ground 3 phase 60 Hz 480 VAC

Single Input 4-Wire Diagram

Illustration 9g03463058
Single input 4-wire diagram
Input: 400 VAC 3 phase 50 Hz 4 wire and ground 940 amps alternating current, with nominal 1200 amps alternating current maximum
Output: 400 VAC 3 phase 50 Hz 4 wire and ground, 903 amps alternating current nominal

Control Panel

Illustration 10g03464376
Typical example of the display panel
(81) Touch screen
(82) USB port
(83) Key switch with two positions (normal/bypass)
(84) Emergency power off (EPO) push button
(85) Horn silence push button
(86) Status LEDs

The control panel is located on the right door of the SIO cabinet. The key switch (83) has a "Bypass" position and a "Normal" position. The EPO button (84) on the control panel, when pressed, opens the K1 and K2 circuit breakers. The EPO button (84), when pressed, removes power from the SIO and flywheel cabinets. There is still voltage in the system after an EPO is pressed.

Note: Different configurations and hardware revisions have different control panels.

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