Cat Electrical 250 Uninterruptible Power Supply (UPS) Electrical System Schematic Manual - PDF DOWNL

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2

FAN_Ribbon 6-B3

SDAT+ SDAT-

3

Cab_Temp+ Cab_Temp-

1 2 3 4 5 6 7 8 9 10

TCK 1 Gnd 2 TDO3 +5 4 TMS5 Unused 6 Unused 7 Unused 8 TDI 9 Gnd 10

1

SDAT + SDAT Unused Unused Unused Unused Unused Unused Temp + Temp -

3

APC Out J1

JTAG I/O J7

Fan Monitor

Fan_110_Hot 4-E3

5

Schematic Uninterruptible Power Supply (UPS) 250 Electrical System

12 11 10 9 8 7 6 5 4 3 2 1

Fan_neut_#6 Fan_Pwr_#6 Fan_neut_#5 Fan_Pwr_#5 Fan_neut_#4 Fan_Pwr_#4 Fan_neut_#3 Fan_Pwr_#3 Fan_neut_#2 Fan_Pwr_#2 Fan_neut_#1 Fan_Pwr_#1

SW_FANS 4-O3

Fan Vacuum Sense J2 Gnd Fan #6 OK, NC Gnd Fan #5 OK, NC Gnd Fan #4 OK, NC Gnd Fan #3 OK, NC Gnd Fan #2 OK, NC Gnd Fan #1 OK, NC

Spare CC Sense J4

Gnd Spare #6 Gnd Spare #5 Gnd Spare #4 Gnd Spare #3 Gnd Spare #2 Gnd Spare #1

Fan Power Out J6

Fan_rtn_#6 Fan_OK_#6 Fan_rtn_#5 Fan_OK_#5 Fan_rtn_#4 Fan_OK_#4 Fan_rtn_#3 Fan_OK_#3 Fan_rtn_#2 Fan_OK_#2 Fan_rtn_#1 Fan_OK_#1

Fan_110_Neut 4-E3

110 Vac In J5

12 11 10 9 8 7 6 5 4 3 2 1

5

4

Unused Unused Neutral Fan Power #6 Neutral Fan Power #5 Neutral Fan Power #4 Neutral Fan Power #3 Neutral Fan Power #2 Neutral Fan Power #1

FAN4-J3

FAN

14 13 12 11 10 9 8 7 6 5 4 3 2 1

4

Power In J3

+24 In +24 In Gnd Gnd

3 110 Neut In 2 Switched Fans 1 110 Vac In

1 2 3 4

FAN+ 4-J3

6

6

BEE1-UP

7

7

8

8 FAN-1

FAN-2

blk

blk

C39

Fan_Pwr_#2 Fan_neut_#2

Fan_Pwr_#3 Fan_neut_#3

Fan_Pwr_#4 Fan_neut_#4

blk

C43

brn

blu

FAN-6

blk

C42

brn

blu

FAN-5

blk

C41

brn

blu

FAN-4

blk

C40

brn

Fan_Pwr_#1 Fan_neut_#1

FAN-3

C44

brn

Fan_Pwr_#5 Fan_neut_#5

blu

brn

Fan_Pwr_#6 Fan_neut_#6

blu

blu

9

9

SW3

SW4

Fan_rtn_#1 Fan_OK_#1

SW5

Fan_rtn_#2 Fan_OK_#2

SW6

Fan_rtn_#3 Fan_OK_#3

SW7

Fan_rtn_#4 Fan_OK_#4

SW8

Fan_rtn_#5 Fan_OK_#5

Fan_rtn_#6 Fan_OK_#6

1 0

1 0

©2000 Caterpillar All Rights Reserved 1 1

Printed in U.S.A.

1 1

1 2

Fans PAGE 5 of 6 A

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1 2

PWR DIST J31

S

1

1 U34

T1 F22

Active Power APS

PWR DIST J30

PWR DIST J5-1

PWR DIST F4

PWR DIST J4-1

PWR DIST F8

PWR DIST J34-1

AC I/F J7-1

AC I/F F4

SSR-1

EPO RESET CONTACT SET 2

K3 A1

K3

AC I/F J3-1

K3 A2

K1 A1

K1

AC I/F J3-2

K1 A2

PWR DIST J5-3

AC I/F J7-2

PWR DIST J4-3

CR1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Gnd Gnd Plus 5V V lcd W/R\ RD\ CE\ C/D\ Unused RESET\ D0 D1 D2 D3 D4 D5 D6 D7 FS Unused

Backlight Power

PWR DIST F5

2

2

*FAN MON J2-3

CR1

SW 4

*FAN MON J2-4

APC

SIO_Ribbon_2 6-L9

6

7

K1 Control + K1 Control K2 Control + K2 Control K3 Control + K3 Control CR2 Control + CR2 Control K1 Status + K1 Status K2 Status + K2 Status K3 Status + K3 Status SDAT + SDAT -

ACI_Ribbon 4-L6

8

SIO_Ribbon_1 6-L8

RS-232_TX+ RS-232_TXModem_TX+ Modem_TXCAN_A_TX+ CAN_A_TXCAN_B_TX+ CAN_B_TXCSNet_TX+ CSNet_TXCSNet_OE+ CSNet_OERC_Out_SDAT+ RC_Out_SDATModem_DTR+ Modem_DTR-

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

RS-232 trans+ RS-232 transModem trans+ Modem transCAN A trans+ CAN A transCAN B trans+ CAN B transCSNet trans+ CSNet transCSNet OE+ CSNet OERC SDAT In+ RC SDAT InModem DTR+ Modem DTR-

9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

SDAT In+ SDAT InUnused Unused SDAT Out+ SDAT OutUnused Unused DSD Temp+ DSD TempUnused Unused Unused Unused Unused Unused Unused Unused Unused Unused

1 0

1 1

1 2 3 4

APC+ 4-J3 APC4-J3

+24 In +24 In Gnd Gnd

SSI J8

SKI C J7

ACI J15

SKI B J6

SIO J14 SKI A J5

SKI 3 J4 DSD J12

SKI 2 J3

Power In J1 SKI 1 J2

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Gate_A Gate_A_Rtn Gate_A' Gate_A'_Rtn Gate_B Gate_B_Rtn Gate_B' Gate_B'_Rtn Gate_C Gate_C_Rtn Gate_C' Gate_C'_Rtn SSI_Temp+ SSI_Temp-

Bot Gate Out Bot Gate Rtn Top Gate Out Top Gate Rtn Unused Unused I Loop In I Loop Rtn HB OK In HB OK Rtn

1 2 3 4 5 6 7 8 9 10

C_Gate_Lo+ C_Gate_LoC_Gate_Hi+ C_Gate_Hi-

1 Bot Gate Out 2 Bot Gate Rtn 3 Top Gate Out 4 Top Gate Rtn Unused 5 Unused 6 7 I Loop In 8 I Loop Rtn HB OK In 9 HB OK Rtn 10

B_Gate_Lo+ B_Gate_LoB_Gate_Hi+ B_Gate_Hi-

Bot Gate Out Bot Gate Rtn Top Gate Out Top Gate Rtn Unused Unused I Loop In I Loop Rtn HB OK In HB OK Rtn

1 2 3 4 5 6 7 8 9 10

A_Gate_Lo+ A_Gate_LoA_Gate_Hi+ A_Gate_Hi-

Bot Gate Out Bot Gate Rtn Top Gate Out Top Gate Rtn Unused Unused I Loop In I Loop Rtn HB OK In HB OK Rtn

1 2 3 4 5 6 7 8 9 10

FW3_Gate_Lo+ FW3_Gate_LoFW3_Gate_Hi+ FW3_Gate_Hi-

Bot Gate Out Bot Gate Rtn Top Gate Out Top Gate Rtn Unused Unused I Loop In I Loop Rtn HB OK In HB OK Rtn

1 2 3 4 5 6 7 8 9 10

FW2_Gate_Lo+ FW2_Gate_LoFW2_Gate_Hi+ FW2_Gate_Hi-

Bot Gate Out Bot Gate Rtn Top Gate Out Top Gate Rtn Unused Unused I Loop In I Loop Rtn HB OK In HB OK Rtn

1 2 3 4 5 6 7 8 9 10

FW1_Gate_Lo+ FW1_Gate_LoFW1_Gate_Hi+ FW1_Gate_Hi-

UIF_Ribbon 6-B4

FCD_Ribbon 3-D4

EPO TRIP J7

SIO4-J3 SIO+ 4-J3

SKI_C_Ribbon 1-N12

UT_Curr_C+ UT_Curr_CUT_C_OK+ UT_C_OK-

SIO_Ribbon_1 6-B8 SKI_B_Ribbon 1-J12

UT_Curr_B+ UT_Curr_BUT_B_OK+ UT_B_OK-

SKI_A_Ribbon 1-F12 SIO_Ribbon_2 6-B6

UT_Curr_A+ UT_Curr_AUT_A_OK+ UT_A_OK-

SKI_3_Ribbon 3-Q5

FW_Curr_3+ FW_Curr_3FW_3_OK+ FW_3_OK-

RS-232_TX+ RS-232_TXModem_TX+ Modem_TXCAN_A_TX+ CAN_A_TXCAN_B_TX+ CAN_B_TXCSNet_TX+ CSNet_TXCSNet_OE+ CSNet_OERC_Out_SDAT+ RC_Out_SDATModem_DTR+ Modem_DTR-

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

RS-232 trans+ RS-232 transModem trans+ Modem transCAN A trans+ CAN A transCAN B trans+ CAN B transCSNet trans+ CSNet transCSNet OE+ CSNet OERC SDAT In+ RC SDAT InModem DTR+ Modem DTR-

RS-232_RX+ RS-232_RXModem_RX+ Modem_RXCAN_A_RX+ CAN_A_RXCAN_B_RX+ CAN_B_RXCSNet_RX+ CSNet_RXRC_Out_SDAT+ RC_Out_SDAT-

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

RS-232 rec+ RS-232 recModem rec+ Modem recCAN A rec+ CAN A recCAN B rec+ CAN B recCSNet rec+ CSNet recRC SDAT Out+ RC SDAT OutUnused Unused Unused Unused Ethernet trans+ Ethernet transEthernet rec+ Ethernet rec-

Ethernet_TX+ Ethernet_TXEthernet_RX+ Ethernet_RX-

SKI_2_Ribbon 3-M5

EPO TRIP J13

SW1

FAN MON F-3

PWR DIST F2

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JTAG J5

CAN A DB-9M J11

CS-Net RJ-45 J8

APC Out J3

EtherNet RJ-45 J9

N

CC Out J6

O

FAN MON J6-1

FAN 1

SW 5

FAN MON J6-5

FAN 3

*FAN MON J2-7

FAN MON F-4

PWR DIST F3

Unused 1 CAN- 2 Gnd 3 CAN+4 Unused 5

MODEM RJ-11 J10

Unused 1 CAN- 2 Gnd 3 Unused 4 Unused 5 Gnd 6 CAN+7 Unused 8 Unused 9

Unused Unused Unused CSNet+ CSNetUnused Unused Unused

1 2 3 4 5 6 7 8

Out+ OutIn+ Unused Unused InUnused Unused

1 2 3 4 5 6 7 8

Unused Unused Tip Ring Unused Unused

1 2 3 4 5 6

P

9

1 0

1 1

Q

FAN MON F-6

7

8

System I/O Isolation

M

SW 3

SW 6

FAN MON J6-7

FAN 4

*FAN MON J2-11

FW_Curr_1+ FW_Curr_1FW_1_OK+ FW_1_OK-

H

FAN 5

FAN MON J6-10

*FAN MON J2-2

FAN MON J6-2

*NOTE: FAN MONITOR SWITCHES REFERENCED TO LOW VOLTAGE DC LOGIC. FAN MON I/F J2 COLOR CODE PIN 1 BROWN PIN 2 BLACK PIN 3 RED PIN 4 BLACK PIN 5 ORANGE PIN 6 BLACK PIN 7 YELLOW PIN 8 BLACK PIN 9 GREEN PIN 10 BLACK PIN 11 BLUE PIN 12 BLACK

*FAN MON J2-6

FAN MON J6-6

*FAN MON J2-8

FAN MON J6-8

SIO Unused 1 232/485+ trans 2 232/485+ rec 3 Unused 4 Gnd 5 RS-232/485 Unused 6 DB-9F 485- trans 7 J1 485- rec 8 Unused 9

Controller PAGE 6 of 6 B

FAN MON J5-1

PWR DIST J2-1

6

1 2

A

*FAN MON J2-10

5

NO-1 Com1 NC-1

APC In J2

SKI_1_Ribbon 3-I5

FAN MON J5-3

FAN MON J6-4

PWR DIST J2-3 FAN MON J6-9

*FAN MON J2-1

PWR DIST J26

NO-2 Com2 NC-2

CC In J7

SW 7

*FAN MON J2-5

CAN B Header J12

FW_Curr_2+ FW_Curr_2FW_2_OK+ FW_2_OK-

FAN MON F-5

FAN MON F-1

EPO_trip4-R2

Power J4

FAN 2

*FAN MON J2-9

EPO BUTTON J6

SW2

SSI_Ribbon 1-H7

FAN MON J5-2

CR1

PWR DIST J25

T2

EPO 6 5 4 3 2 1

PWR DIST J1-1

Com1 NC1 Com2 NO2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

SIO J16

Gate A Gate A rtn Gate A' Gate A' rtn Gate B Gate B rtn Gate B' Gate B' rtn Gate C Gate C rtn Gate C' Gate C rtn Temp + Temp -

SDAT_TX+ SDAT_TXSPARE_TX+ SPARE_TXSDAT_RX+ SDAT_RXDISPLAY_RDY+ DISPLAY_RDYEPO+ EPO-

1 Serial trans+ 2 Serial trans3 Spare trans+ 4 Spare transSeial Rec+ 5 6 Serial Rec7 Display Ready+ 8 Display ReadyEPO+9 EPO- 10

PWR DIST F7

F24

3

FAN MON J6-3

1 2 3 4

K1_Control+ K1_ControlK2_Control+ K2_ControlK3_Control+ K3_ControlCR2_Control+ CR2_ControlK1_Status+ K1_StatusK2_Status+ K2_StatusK3_Status+ K3_StatusSDAT+ SDAT-

FCD J9

TFC_I_Out+ TFC_I_OutTFC_Gate_Lo+ TFC_Gate_LoTFC_Gate_Hi+ TFC_Gate_HiTFC_Temp+ TFC_TempBFC_I_Out+ BFC_I_OutBFC_Gate_Lo+ BFC_Gate_LoBFC_Gate_Hi+ BFC_Gate_HiBFC_Temp+ BFC_Temp-

JTAG J8

EPO TRIP Unused

RS-232 rec+ RS-232 recModem rec+ Modem recCAN A rec+ CAN A recCAN B rec+ CAN B recCSNet rec+ CSNet recRC SDAT Out+ RC SDAT OutUnused Unused Unused Unused Ethernet trans+ Ethernet transEthernet rec+ Ethernet rec-

RS-232_RX+ RS-232_RXModem_RX+ Modem_RXCAN_A_RX+ CAN_A_RXCAN_B_RX+ CAN_B_RXCSNet_RX+ CSNet_RXRC_Out_SDAT+ RC_Out_SDAT-

DCS J13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

UIF4-J2

4 KEYSWITCH IN J10

1 2

Ethernet_TX+ Ethernet_TXEthernet_RX+ Ethernet_RX-

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

5

TFC I Out Gnd TFC Gate Lo+ TFC Gate LoTFC Gate Hi+ TFC Gate HiTFC Temp+ TFC TempBFC I Out Gnd BFC Gate Lo+ BFC Gate LoBFC Gate Hi+ BFC Gate HiBFC Temp+ BFC Temp-

APC I/O J2

Comes with Overlay

TCK GND TDO PLUS 5 Unused Unused Unused Unused TDI GND

DCS Duty In+ DCS Duty InUnused Unused Unused Unused Unused Unused Shutdown Out+ Shutdown Out-

UIF J17

Clear

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

FWI-2 J10

Enter

FWI_Ribbon_2 3-B8

KEYPAD IN J5

UIF+ 4-J2

CC Out 1-1 CC Out 2-1 CC Out 3-1 CC Out 4-1 CC Out 5-1 CC Out 6-1 CC Out 7-1 CC Out 8-1 CC Out 1-2 CC Out 2-2 CC Out 3-2 CC Out 4-2 CC Out 5-2 CC Out 6-2 CC Out 7-2 CC Out 8-2

Serial trans+ Serial transSpare trans+ Spare transSeial Rec+ Serial RecDisplay Ready+ Display ReadyEPO+ EPO-

TFC_Temp+ TFC_TempTHALL_1+ THALL_1THALL_2+ THALL_2Spare_Temp+ Spare_TempVac+ VacInlet_Temp+ Inlet_TempComm_Sensor+ Comm_SensorTop_Brng_Temp+ Top_Brng_Temp+

PB1 PB2 PB3 PB4 PB5 PB6 GND

24 Vdc 1 24 Vdc 2 GND3 GND4

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7

TCK GND TDO PLUS 5 Unused Unused Unused Unused TDI GND

SDAT_TX+ SDAT_TXSPARE_TX+ SPARE_TXSDAT_RX+ SDAT_RXDISPLAY_RDY+ DISPLAY_RDYEPO+ EPO-

APS Controller

TFC Temp + TFC Temp THall 1 + THall 1 THall 2 + THall 2 Spare temp + Spare temp Vac + vac Inlet Temp + Inlet Temp Comm Sensor + Comm Sensor Top Brng Temp + Top Brng Temp -

User Interface

U35

FAN MON F-2

POWER OUT1 GND2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

UIF_Ribbon 6-R3

FAN J18

Gnd Gnd Plus 5V V lcd W/R\ RD\ CE\ C/D\ Unused RESET\ D0 D1 D2 D3 D4 D5 D6 D7 FS Unused

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

UIF Backlight J4

Power J1

LCD I/O J3

KS1 GND KS3 KS4 GND KS6

4

SDAT + SDAT Unused Unused Unused Unused Unused Unused Temp + Temp -

FWI_Ribbon_1 3-B7

1 2 3 4 5 6

Cab_Temp+ Cab_Temp-

1 2 3 4 5 6 7 8 9 10

BFC_Temp+ BFC_TempArm_Temp+ Arm_TempLam_Temp+ Lam_TempBHALL_1+ BHALL_1BHALL_2+ BHALL_2Horz_Accel+ Horz_AccelVert_Accel+ Vert_AccelBot_Brng_Temp+ Bot_Brng_Temp+

1 2

SDAT+ SDAT-

FWI-1 J11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

EPO TRIP EPO TRIP -

FAN_Ribbon 5-G3

DCI J19

BFC Temp + BFC Temp Arm Temp + Arm Temp Lam Temp + Lam Temp BHall 1 + BHall 1 BHall 2 + BHall 2 Horz. accel + Horz. accel Vert. accel + Vert. accel Bot Brng Temp. + Bot Brng Temp. -

1 2 3 4

3

SDAT + SDAT Unused Unused Unused Unused DC Plus Out Gnd DC Minus Out Gnd

24 Vdc 24 Vdc GND GND

DC_Plus_V+ DC_Plus_VDC_Minus_V+ DC_Minus_V-

1 2 3 4 5 6 7 8 9 10

CC In 1-1 CC In 2-1 CC In 3-1 CC In 4-1 CC In 5-1 CC In 6-1 Rem EPO NO IN-1 Rem EPO NC IN-1 CC In 1-2 CC In 2-2 CC In 3-2 CC In 4-2 CC In 5-2 CC In 6-2 Rem EPO NO IN-2 Rem EPO NC IN-2

SDAT+ SDAT-

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

DCI_Ribbon 2-L3

R

S

1 2

PWR DIST F1

PWR DIST J3-1

AC I/F J7-3

SSR-2

AC I/F F5

AC I/F J3-3

EPO RESET CONTACT SET 1

SW 8

FAN MON J6-11

K2 A1

PWR DIST J32

FAN 6

K2

VACUUM PUMP

K2 A2

PWR DIST J33

AC I/F J3-4

*FAN MON J2-12

FAN MON J6-12

AC I/F J7-4

PWR DIST J3-3

A

B

C

D

E

F

G

H

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L

M

N

O

P

Q

R

S

K3

1

2

Q1 MOV

Filter

Network

A2

A1

14

13

J4

EMI

Input_B 4-B9

MOV

Filter

EMI

Network

EMI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

1

1

2

2

Filter

EMI-3 K3_aux13

Line Inductor K1

CT-4

DCI

J1

K3_coil_A2 Contactor Ctrl 1-F6, 1-N6, 4-O1

K2

3

CT-1

F1 -

+

-

+

CT-3 F3

1 2 3

J8

TCK 1 Gnd 2 TDO3 +5 4 TMS5 Unused 6 Unused 7 Unused 8 TDI 9 Gnd 10

4

5

K2_coil_A2

1 Thermistor+ 2 Thermistor-

L4

Flywheel Inductor

NEUT

L5

6

NEUT

Flywheel Inductor

Typical AC Cap Bank

Flywheel Inductor

L6

Lo_Fuse_Sense_#1 Lo_Fuse_Sense_#2 Lo_Fuse_Sense_#3 Lo_Fuse_Sense_#4 Lo_Fuse_Sense_#5 Lo_Fuse_Sense_#6 Lo_Fuse_Sense_#7 Lo_Fuse_Sense_#8

Contactor Ctrl 1-F6, 1-N3, 4-O1

AC Voltage Sense 4-P8, 1-D6, 1-P5

Cbank_B

NEUT

Gate_A Gate_A_Rtn Gate_A' Gate_A'_Rtn Gate_B Gate_B_Rtn Gate_B' Gate_B'_Rtn Gate_C Gate_C_Rtn Gate_C' Gate_C'_Rtn SSI_Temp+ SSI_Temp-

7

Contactor Sense 1-N3, 1-F5, 4-M4

K2_coil_A1

SSI

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4

SSI4-K6

AC Voltage Sense 4-P8, 1-D6, 1-L6

K2_aux14

J9 Cbank_A

SSI+ 4-K6

J7

DC_Plus_V+ DC_Plus_VDC_Minus_V+ DC_Minus_V-

Lo Fuse Sense J4

1 2 3 4 5 6 7 8 9 10

C'G unused C'K

1 2

1 2 3

CG CK

Inverter_B

J3

J6

K2_aux13

Inverter_C

APC I/O J1

Power In J7

+24 In +24 In Gnd Gnd

6

Contactor Ctrl 1-N3, 1-N6, 4-O1

AC Voltage Sense 4-P8, 1-P5, 1-L6

J2

Static Switch Interface

K1_coil_A2

Curr. Sense In 4-Q4

J5

5

Output_C

Inverter_A

Hi Fuse Sense J3

Hi_Fuse_Sense_#1 Hi_Fuse_Sense_#2 Hi_Fuse_Sense_#3 Hi_Fuse_Sense_#4 Hi_Fuse_Sense_#5 Hi_Fuse_Sense_#6 Hi_Fuse_Sense_#7 Hi_Fuse_Sense_#8

Contactor Sense 1-N3, 1-N5, 4-M4

B'G unused B'K

J4

Gate A Gate A rtn Gate A' Gate A' rtn Gate B Gate B rtn Gate B' Gate B' rtn Gate C Gate C rtn Gate C' Gate C rtn Temp + Temp -

K1_coil_A1

1 2

BG BK

1 2 3

J8

J6

Input_C

Input_A_CT-

Input_A_CT+

Input_B_CT-

Input_B_CT+

Input_C_CT-

Input_C_CT+

K1_aux14

A'G unused A'K

K1_aux13

Input_B

BOY wiring convention Brown - Phase A Orange - Phase B Yellow - Phase C Gray - Neutral Green - Ground

AG AK

1 2

Input_A

5

DC Bus Sense

Curr. Sense Out 4-Q4

Output_B

3

DCI_Ribbon 6-B2

SDAT+ SDAT-

Lo Fuse #1 In Lo Fuse #2 In Lo Fuse #3 In Lo Fuse #4 In Lo Fuse #5 In Lo Fuse #6 In Lo Fuse #7 In Lo Fuse #8 In

Output_A

NEUT

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8

F6

DC Common

F5

DC Minus

F4

Hi Fuse #1 In Hi Fuse #2 In Hi Fuse #3 In Hi Fuse #4 In Hi Fuse #5 In Hi Fuse #6 In Hi Fuse #7 In Hi Fuse #8 In Unused Unused

Output_B 4-B11

JTAG I/O J5

DC Plus

13

Thermistor

Output_C_CT-

14

Output Neut Output_C_CT+

THERM1

4

Output_A 4-B11 Output_B_CT-

13

A1

Output_B_CT+

14

A2

Output_A_CT-

A1

Output_A_CT+

NEUT

A2

-

+

Q3

Input Neut

Input Gnd

DC Interface

Output C

-

+

Input C

DCI4-K5

APC Out J1

Power In J2

+24 In +24 In Gnd Gnd

1 2 3 4

DCI+ 4-K5

Output B

-

+

CT-6

CT-2

Inverter Node

F2

Input B

SDAT + SDAT Unused Unused Unused Unused DC Plus Out Gnd DC Minus Out Gnd

Output A

-

CT-5

+

Input A

4

Contactor Sense 1-F5, 1-N5, 4-M4

K3_coil_A1

Inv_B 4-B9

L1

Q2

J2

Inv_A 4-B9

NEUT

3

J3

K3_aux14

Input_A 4-B8

6

7

7

R = 2 ea @ 18 k, 11 Watt C = 8 ea @ 30 uF, 370 Vac

SSI_Ribbon 6-I6

Reference Designators are Cbank1, Cbank2 and Cbank3 for both R and C. DC_Bus+ 2-D8, 3-A1 SKiiP-A

8

SKiip Pack IGBT

85551-1 jumpers the components for Phase A 85551-2 jumpers the components for Phase B 85551-3 jumpers the components for phase C 85551-4 x 3 jumpers the neutrals for each Cbank

SKiiP-B

SKiiP-C

SKiip Pack IGBT

SKiip Pack IGBT

DC_Bus+ 3-A1, 1-B8

8

8 C1

C3

R1

Hi_Fuse_Sense_#1

Hi_Fuse_Sense_#2

Interface Control

Interface Control

F13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out

SKiiP Interface

A

B

C

D

E

G

H

FUSABLE LINK

Lo_Fuse_Sense_#2

C2

R7

F23 FUSABLE LINK

Lo_Fuse_Sense_#3

C4

R8

F29

C6

R9

FUSABLE LINK

FUSABLE LINK

Lo_Fuse_Sense_#4

Lo_Fuse_Sense_#5

C8

R10

Lo_Fuse_Sense_#6

C10

R11

C12

R12

DC_Bus3-A3, 1-B10

Bot Gate In Bot Gate Rtn Top Gate In Top Gate Rtn Unused Unused I Loop Out I Loop Rtn HB OK Out HB OK Rtn

1 0

1 0

1 1

1 1

UT_Curr_C+ UT_Curr_CUT_C_OK+ UT_C_OK-

C_Gate_Lo+ C_Gate_LoC_Gate_Hi+ C_Gate_HiSKI_C_Ribbon 6-I7

I

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DC Link PAGE 2 of 6

R

1

Contactor Ctrl 1-F6, 1-N3, 1-N6

SKiip Pack IGBT

SW_FANS_T2 4-Q3 ACI_Inv110_Hot 4-N2

UIF PWR J12

APC PWR J13

SIO PWR J14

FAN PWR J15

EPO PWR J16

FWI PWR J17

110 Vac (T1) 6

6

F9

1 2 3 4

FWI+ 4-J4 FWI4-J4

J6

APC I/O J2

Top Fw J5 Comm/Accel Interface J9

Power In J1

Power Out J8

Vacuum RJ-45 J10

J7

Bot Brng Temp1 + Bot Brng Temp2 + Bot Brng Temp2 Bot Brng Temp1 -

TFC Temp + TFC Temp THall 1 + THall 1 THall 2 + THall 2 Spare temp + Spare temp Source 2 Xover Gnd Source 1 Xover Gnd Top Brng Temp1 + Top Brng Temp2 + Top Brng Temp2 Top Brng Temp1 -

1 2 3 4

1 2 3 4 5 6 7 8 9 10 11 12

Input_A 1-E3

T1

F15

H4

X1

Input_B 1-E2

F16

H1

X2

F22

BLK

F1

9 Vac Gauge 1 2 3 4 5 6 7 8

F17

CR2

Inv_A

T2

H4

PWR OUT 24V J3

F24 X1

24Vdc 1 24Vdc 2 Gnd 3 Gnd 4

SKI_A+ 1-D11 SKI_A1-D11

SKI B PWR J23

24Vdc 1 24Vdc 2 Gnd 3 Gnd 4

SKI_B+ 1-H11 SKI_B1-H11

24Vdc 24Vdc Gnd Gnd

SKI C PWR J24

ACI+ 4-J2 ACI4-J2

1 2 3 4

12

D100

22i

12n

K1_coil_A1 K1_coil_A2 K2_coil_A1 K2_coil_A2 K3_coil_A1 K3_coil_A2

Output_A_CT+ Output_A_CTOutput_B_CT+ Output_B_CTOutput_C_CT+ Output_C_CTInput_A_CT+ Input_A_CTInput_B_CT+ Input_B_CTInput_C_CT+ Input_C_CT-

CT I/O J2

JTAG I/O J6

AC Interface

6

APC In J10

Outpt Volts J12 Power In J4

+24 In +24 In Gnd Gnd

1-K3

PWR OUT GND J4

Buck Regulator

Inv_B 1-K3 Vac

F18

H1

5

Invtr Volts J11

Input Volts J1 7

8

AC Voltage Sense 1-D6, 1-P5, 1-L6

NEUT

9

F1

BCK

X2

PWR In Un-Reg J1

1 0 CR2_Control 4-M3

1 2 3 4

SKI A PWR J22

DSD-

K1 Control + K1 Control K2 Control + K2 Control K3 Control + K3 Control CR2 Control + CR2 Control K1 Status + K1 Status K2 Status + K2 Status K3 Status + K3 Status SDAT + SDAT -

SKI_C1-L11 SKI_C+ 1-L11 SKI_33-P5 SKI_3+ 3-P5 SKI_23-L5 SKI_2+ 3-L5 SKI_13-H5 SKI_1+ 3-H5

M

Vacuum_110_Neut 4-E4

Sig Com

DSD+

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

110 Coil Control J3

ACI

RED

Vac Pump Vacuum_110_Hot 4-E4

INSIDE PUCK

24Vdc 1 24Vdc 2 Gnd 3 Gnd 4

1 2 3 4

SKI 3 PWR J27 24Vdc 24Vdc Gnd Gnd

SKI 2 PWR J28

Field Coil Ground 2-P9

+24 Gnd Gauge Out

DSD PWR J21

K1_Control+ K1_ControlK2_Control+ K2_ControlK3_Control+ K3_ControlCR2_Control+ CR2_ControlK1_Status+ K1_StatusK2_Status+ K2_StatusK3_Status+ K3_StatusSDAT+ SDAT-

110 In J7

4 3 2 1

SIG5247 2-P9

Toroidal Choke Assy

INSIDE PUCK

SSI+ 1-F7 SSI1-F7

CR 24Vdc J9

P3

8

A B C D E F G H J K L M N P R S T U V

1 2 3 4

P2

24Vdc 1 24Vdc 2 Gnd 3 Gnd 4

Contact Status J8

ACI_Ribbon 6-B7

Inverter_C Inverter_B Inverter_A

INSIDE PUCK

SKI 1 PWR J29

PWR In GND J9

FCD+ 3-A3 FCD3-A3

Output_C Output_B Output_A

G

1 2 3 4

brn blk red blk orn blk yel blk grn blk blu blk

FW-1

PWR In 24V J8

7

PWR In GND J2

1 0

CR2_Return 4-M3

INSIDE PUCK

+

+24 Gnd Gauge Out

1 2 3 4 5 6 7 8 9 10

1 0

+24 In +24 In Gnd Gnd

Flywheel Interface

brn blk red blk orn blk yel blk grn blk blu blk vio blk

NEUT

AC In HOT J25

1 2 3 4

TFC Temp + TFC Temp THall 1 + THall 1 THall 2 + THall 2 Spare temp + Spare temp Vac + vac Inlet Temp + Inlet Temp Comm Sensor + Comm Sensor Top Brng Temp + Top Brng Temp -

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Sig Com

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

APC I/O J3

+24 Gnd Gauge Out Unused Signal Com Unused Unused Unused

TFC_Temp+ TFC_TempTHALL_1+ THALL_1THALL_2+ THALL_2Spare_Temp+ Spare_TempVac+ VacInlet_Temp+ Inlet_TempComm_Sensor+ Comm_SensorTop_Brng_Temp+ Top_Brng_Temp+

Bot Fw J4

BFC Temp + BFC Temp Arm Temp + Arm Temp Lam Temp + Lam Temp BHall 1 + BHall 1 BHall 2 + BHall 2 Hall Source 1 Source 1 Xover Hall Source 2 Source 2 Xover

P1

1 2 3 4 5 6 7 8

9

BFC Temp + BFC Temp Arm Temp + Arm Temp Lam Temp + Lam Temp BHall 1 + BHall 1 BHall 2 + BHall 2 Horz. accel + Horz. accel Vert. accel + Vert. accel Bot Brng Temp. + Bot Brng Temp. -

+CAC Pwr +CAC Pwr Gnd Gnd

FWI_Ribbon_2 6-I4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4

8

BFC_Temp+ BFC_TempArm_Temp+ Arm_TempLam_Temp+ Lam_TempBHALL_1+ BHALL_1BHALL_2+ BHALL_2Horz_Accel+ Horz_AccelVert_Accel+ Vert_AccelBot_Brng_Temp+ Bot_Brng_Temp+

Gnd Gnd +CAC Pwr +CAC Pwr Comm Sensor + Comm Sensor Vert. Accel. + Vert. Accel. Horz. Accel. + Horz. Accel. -

FWI_Ribbon_1 6-I2

N

AC In Neut J26

24Vdc 24Vdc Gnd Gnd

FWI

AC In HOT J30

1 2 3 4

A B C D E F G H J K L M N P R S T U V

7

AC In Neut J31

24Vdc 24Vdc Gnd Gnd

Field Coil

1 2 3 4

F8

24Vdc 1 24Vdc 2 Gnd 3 Gnd 4

SSI PWR J20

Power Distribution

110 Vac (T2)

FCD PWR J19

1 2 3 4 5 6

1 2 3 4 24Vdc 24Vdc Gnd Gnd

1 2 3 4 24Vdc 24Vdc Gnd Gnd

1 2 3 4 24Vdc 24Vdc Gnd Gnd

1 2 3 4 24Vdc 24Vdc Gnd Gnd

1 2 3 4 24Vdc 24Vdc Gnd Gnd

1 2 3 4

ACI PWR J11

DCI+ 2-G3 DCI2-G4

Input C Input B Input A Input Neut

DSI PWR J10

VACUUM HOT J32

24Vdc 1 24Vdc 2 Gnd 3 Gnd 4

4 3 2 1

VACUUM Neut J33

DCI PWR J18

4 Curr. Sense In 1-C6

Input_C Input_B Input_A

FAN PWR J2

24Vdc 24Vdc Gnd Gnd

1 2 3 4 24Vdc 24Vdc Gnd Gnd

1 2 3 4

ACI Inv J3

SW_FANS_T2 4-D3

Inverter C Inverter B Inverter A Inverter Neut

SW FANS J1

Hot Hot Neut Neut

1 2 3 4 Hot Hot Neut Neut

1 2 3 4

SW FANS J34

3

SW_FANS_T1 4-C3

TCK 1 Gnd 2 TDO3 +5 4 TMS5 Unused 6 Unused 7 Unused 8 TDI 9 Gnd 10

K3 PWR J4

Hot Hot Neut Neut

1 2 3 4 Hot Hot Neut Neut

1 2 3 4 Hot Hot Neut Neut

1 2 3 4 Hot Hot Neut Neut

1 2 3 4 Hot Hot Neut Neut

1 2 3 4

5 6 7 8 9 10

FW_Curr_3+ FW_Curr_3FW_3_OK+ FW_3_OK-

5

ACI In J5

SKI_3_Ribbon 6-I10

F7

Contactor Sense 1-N3, 1-F5, 1-N5

PWD

LITE PWR J6

K3_110_Neut 4-C2

4 3 2 1

SKI_2_Ribbon 6-I10

4

LITE SW J7

K3_110_Hot 4-C2

Curr. Sense Out 1-Q5 FWI+ 3-C10 FWI3-C10

Bot Gate In Bot Gate Rtn Top Gate In Top Gate Rtn Unused Unused I Loop Out I Loop Rtn HB OK Out HB OK Rtn

+24 In +24 In Gnd Gnd 1 2 3 4

5 6 7 8 9 10

SKI_3+ 4-J8 SKI_34-J8

APC I/O J3

2 EPO_trip6-N6

Output C Output B Output A Output Neut

SKI_1_Ribbon 6-I11

Power In J2

FW_Curr_2+ FW_Curr_2FW_2_OK+ FW_2_OK-

+24 In +24 In Gnd Gnd 1 2 3 4

5 6 7 8 9 10

FW2_Gate_Lo+ 1 FW2_Gate_Lo- 2 FW2_Gate_Hi+ 3 FW2_Gate_Hi- 4

5

SKI_2+ 4-J8 SKI_24-J8

FW_Curr_1+ FW_Curr_1FW_1_OK+ FW_1_OK-

SKI_1+ 4-J9 SKI_14-J9

SKI-3

APC I/O J3 Bot Gate In Bot Gate Rtn Top Gate In Top Gate Rtn Unused Unused I Loop Out I Loop Rtn HB OK Out HB OK Rtn

Power In J2

Bot Gate In Bot Gate Rtn Top Gate In Top Gate Rtn Unused Unused I Loop Out I Loop Rtn HB OK Out HB OK Rtn

FW1_Gate_Lo+ 1 FW1_Gate_Lo- 2 FW1_Gate_Hi+ 3 FW1_Gate_Hi- 4

1 2 3 4

+24 In +24 In Gnd Gnd

4

SKI-2

APC I/O J3

FW3_Gate_Lo+ 1 FW3_Gate_Lo- 2 FW3_Gate_Hi+ 3 FW3_Gate_Hi- 4

SKI-1

Power In J2

Vacuum_110_Neut 3-K9 Vacuum_110_Hot 3-K8

24 Vdc Trip

SW_FANS 5-H5

K1 AC Out Input Neut K2 AC Out Inverter Neut

SKiiP Interface

1 2 3 4

SKiiP Interface

Hot Hot Neut Neut

SKiiP Interface

FCD_Ribbon 6-I5

SKiiP I/O J1

Contact Set #2

CR2_Return 4-D10

FAN+ 5-H4 FAN5-H4 EPO_trip+ 4-R3

24Vdc 24Vdc Gnd Gnd

SKiiP I/O J1

Fan_110_Neut 5-H5

Reset

CR1

1 2 3 4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out

SKiiP I/O J1

ACI_Inv110_Neut 4-N2 Fan_110_Hot 5-H6

Contact Set #1

CR2_Control 4-D10

Input Hot Input Neut Inverter Hot Inverter Neut

1 2 3 4 5 6 7 8 9 10 11 12 13 14 Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out

3

Push to Reset

EPO_trip+ 4-J4

APC+ 6-C11 APC6-C11 SIO+ 6-M6 SIO6-M6

1 2 3 4

Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out

SW_FANS_T1 4-Q3

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out 1 2 3 4 5 6 7 8 9 10 11 12 13 14

DC-

BFC-

BFC+

TFC I Out Gnd TFC Gate Lo+ TFC Gate LoTFC Gate Hi+ TFC Gate HiTFC Temp+ TFC TempBFC I Out Gnd BFC Gate Lo+ BFC Gate LoBFC Gate Hi+ BFC Gate HiBFC Temp+ BFC Temp-

J4

K3_110_Neut 4-R3

1 2 3 4 5 6 7 8 9 10 11 12 13 14

NEUT

J7 J8

ACI+ 4-L7 ACI4-L7 UIF+ 6-Q3 UIF6-Q3

K3_110_Hot 4-R3

Interface Control

Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out

DC_Bus2-D10, 1-B10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Com

J9

TFC_I_Out+ TFC_I_OutTFC_Gate_Lo+ TFC_Gate_LoTFC_Gate_Hi+ TFC_Gate_HiTFC_Temp+ TFC_TempBFC_I_Out+ BFC_I_OutBFC_Gate_Lo+ BFC_Gate_LoBFC_Gate_Hi+ BFC_Gate_HiBFC_Temp+ BFC_Temp-

J5 J6 TFC-

Power In J2

TFC+

FCD4-K5

+24 In +24 In Gnd Gnd

Interface Control

Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out

Interface Control

J1

ACI_Inv110_Neut 4-D3 ACI_Inv110_Hot 4-D3 ACI_Input110_Neu 4-B2 ACI_Input110_Hot 4-B2

CR1(K3) Out CR1(K3) Rtn CR2 Out CR2 Rtn

2

1 2 3 4

DSI-

ACI_Input110_Neu 4-N2

2

FCD+ 4-K5

DSI+

ACI_Input110_Hot 4-N2

Field Coil Driver

K1_aux13 K1_aux14 K2_aux13 K2_aux14 K3_aux13 K3_aux14

SKiip Pack IGBT

K1 Aux In 1 Gnd 2 K2 Aux In 3 Gnd 4 K3 Aux In 5 Gnd 6 Unused 7 Unused 8

SKiip Pack IGBT

11L

SKiiP-2

J3

12k

SKiiP-1

SKiiP-3

21L

FCD

CT A In 1 Gnd 2 CT B In 3 Gnd 4 CT C In 5 Gnd 6 CT A Out 7 Gnd 8 CT B Out 9 Gnd 10 CT C Out 11 Gnd 12

FCD

1 2

S

1 DC_Bus+ 2-D8, 1-B8

DC+

1

3

9

F31

1 2 3 4 5 6 7 8 9 10

1 2 3 4

UT_Curr_B+ UT_Curr_BUT_B_OK+ UT_B_OK-

SKI_C+ 4-J8 SKI_C4-J8

SKI_B_Ribbon 6-I8

F

SIG5247 4-F7

DC-DC Supply

APC I/O J3

+24 In +24 In Gnd Gnd

Bot Gate In Bot Gate Rtn Top Gate In Top Gate Rtn Unused Unused I Loop Out I Loop Rtn HB OK Out HB OK Rtn

B_Gate_Lo+ B_Gate_LoB_Gate_Hi+ B_Gate_Hi-

SKI_A_Ribbon 6-I9

1 2

FUSABLE LINK

SKI-C

Power In J2

1 2 3 4 5 6 7 8 9 10

1 2 3 4

SKI_B+ 4-K7 SKI_B4-K7

UT_Curr_A+ UT_Curr_AUT_A_OK+ UT_A_OK-

A_Gate_Lo+ A_Gate_LoA_Gate_Hi+ A_Gate_Hi-

SKI_A+ 4-K6 SKI_A4-K7

DCS

F32

FUSABLE LINK

SKiiP Interface APC I/O J3

+24 In +24 In Gnd Gnd

Bot Gate In Bot Gate Rtn Top Gate In Top Gate Rtn Unused Unused I Loop Out I Loop Rtn HB OK Out HB OK Rtn 1 2 3 4 5 6 7 8 9 10

1 2 3 4

+24 In +24 In Gnd Gnd

1 1

Power In J2

F14

FUSABLE LINK

Lo_Fuse_Sense_#1

SKI-B

APC I/O J3

Hi_Fuse_Sense_#6

F30

FUSABLE LINK

R6

SKiiP I/O J1

SKI-A

Power In J2

F12

FUSABLE LINK

Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out

1 2 3 4 5 6 7 8 9 10 11 12 13 14 Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out

SKiiP Interface

F10

NEUT

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Shld Bot In Err Out Top In OvrTmp +24 In +24 In +15 I/O +15 I/O Pwr Gnd Pwr Gnd Temp Out Sig Gnd I Out

SKiiP I/O J1

Hi_Fuse_Sense_#5

F25

FUSABLE LINK

C11

R5

Ground 4-F8

DC_Bus2-D10, 3-A3

SKiiP I/O J1

Hi_Fuse_Sense_#4

F20

FUSABLE LINK

C9

R4

9

Interface Control Inverter Section

1 0

C7

R3

Hi_Fuse_Sense_#3

F11 FUSABLE LINK

9

C5

R2

T3 1

Output_A 1-N4

1 1

TB2-F2

3

~

D1

F19

C13

C14

~

1 1

-

1 1

TB2-F1

F26

Surge1 1 2 3 4 5 6 7 8 9 10

1 2

A

B

C

D

E

F

Gnd to FWI Gnd J6 +Pwr +Pwr Comm Sensor + Comm Sensor Vert. Accel. + Vert. Accel. Horz. Accel. + Horz. Accel. -

F21

Output_B 1-N4

2

4

F27

Comm/Accel Assembly

Flywheel G

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