EN CAT Engine - Generator Set Flywheel 750 3-Wire Uninterruptible Power Supply Electrical System Sch

UENR3995 July 2013

Flywheel 750 3-Wire Uninterruptible Power Supply Electrical System CD71-UP

© 2013 Caterpillar, All Rights Reserved

Printed in U.S.A.

Flywheel 750 3-Wire UPS PART NUMBER 227-4840 242-7429 259-3199 299-2226 420-5352 420-5354 420-5355 420-5356 420-5357 420-5358 420-5428 420-5430 420-5442 435-9965 435-9978 435-9983 435-9984 435-9990 EXTRA

NAME

DESCRIPTION

PAGE

EPO PB1 EMI BOARD EMI BOARD GSM BREAKERS PDDC BOARD APC3 BOARD SSD BOARD BCI BOARD SSS BOARD PDAC BOARD UGD BOARD FGD BOARD CIO BOARD RPS BOARD FAN BOARD VCI BOARD FWI BOARD FCD BOARD

EMERGENCY POWER OFF BUTTON ELECTROMAGNETIC INTERFACE BOARD ELECTROMAGNETIC INTERFACE BOARD GEN START MODULE BREAKERS POWER DISTRIBUTION DC BOARD CONTROL BOARDS STATIC SWITCH DRIVER BOARD BREAKER CONTROLLER INTERFACE BOARD STATIC SWITCH SNUBBER BOARD POWER DISTRIBUTION AC BOARD UTILITY GATE DRIVER BOARD FLYWHEEL GATE DRIVER BOARD CUSTOMER INTERFACE ROTOR POSITION SENSOR FAN INTERFACE BOARD VOLTAGE CURRENT INTERFACE BOARD FLYWHEEL INTERFACE BOARD FIELD COIL DRIVER BOARD

12 2, 17 4, 17 2, 17 11 4, 5, 6, 7, 9, 13 , 17 3, 4, 17 12, 17 3, 17 10, 17 5, 6 6 14, 17 8 9, 16 2, 3, 7, 17 8, 16 7

MBP ESS SIO FPU THY MCB CT CAP FNI THERM

MAINTENANCE BYPASS EXTERNAL SOURCE SYNC SYSTEM INPUT / OUTPUT FLYWHEEL POWER UNIT THYRISTOR MANUAL CIRCUIT BREAKER CURRENT TRANSFORMER CAPACITOR FAN NETWORK INTERFACE THERMISTOR

15 15 17 16 3,4 2 2, 5, 6, 17 4, 7 ,16, 17 9, 16 5, 6, 7

PAGE NAMES PAGE 1 PAGE 2 PAGE 3 PAGE 4 PAGE 5 PAGE 6 PAGE 7 PAGE 8 PAGE 9 PAGE 10 PAGE 11 PAGE 12 PAGE 13 PAGE 14 PAGE 15 PAGE 16 PAGE 17

FUSE TABLE INPUT CONNECTIONS BYPASS CIRCUIT STATIC SWITCH CONNECTION PAGE UTILITY GATE DRIVER CONNECTIONS FLYWHEEL GATE DRIVER CONNECTIONS FLYWHEEL CONNECTIONS INTERNAL FLYWHEEL CONNECTIONS FAN CONNECTIONS POWER DISTRIBUTION AC PAGE POWER DISTRIBUTION DC PAGE BREAKER CONTROLLER CONNECTIONS CONTROL BOARD CONNECTIONS CUSTOMER INTERFACE CONNECTIONS MBP INTERFACE / ESS OPTIONS FPU CABINET ASSEMBLY SIO CABINET ASSEMBLY

6

5

3

4

2

1

F

F

E

E

S750 3-WIRE SYSTEM SCHEMATIC D

D

FUSE TABLE FUSE CAT Part # RATING TYPE F1 200-6265 600V, 4A ATQR F2 200-6265 600V, 4A ATQR F3 200-6266 600V, 4A ATQR F4 200-6266 600V, 4A ATQR F5 200-6266 600V, 4A ATQR F6 200-6266 600V, 4A ATQR F7 420-5389 700VAC, 1250A LI BLADE F8 420-5389 700VAC, 1250A LI BLADE F9 420-5389 700VAC, 1250A LI BLADE F10 - F33 438-0389 600VAC, 3A ATDR F34 240-1903 600VAC, 15A ATQR F35 240-1903 600VAC, 15A ATQR F36 240-1903 600VAC, 15A ATQR F37 201-7590 600V, 600A AJT600 F38 201-7590 600V, 600A AJT600 F39 201-7590 600V, 600A AJT600

C

B

PAGE 2 2 2 2 2 2 4 4 4 9 2 2 2 3 3 3

C

B

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 1 OF 17 6

5

4

3

2

1

6

5

3

4

1

2

F

F

Bypass / Dual Source Input

Local Bypass Option Note: Reference additional schematics for other bypass configurations

Components installed with Local Bypass and Dual Source Options.

Byp In A

Byp A/3.B1

Byp In B

Out A/3.B20

Byp B/3.B1

Out B/3.B20

Byp C/3.A1

Blk Blk Blk

Byp In C

E

Wht

TVSS2

Out C/3.A20

L5

1

2

A1

A2

Fan TB-5 / 9.N8

3

4

B1

B2

Fan TB-15/ 9.M8

5

6

C1

C2

Fan TB-25/ 9.M8

For Single Input Systems with Local Bypass, wire as indicated.

1

3

2

F5, F6 ATQR, 4A, 4 600V

EMI EMI EMI PWA PWA PWA 242-7429 242-7429 242-7429

F34, F35, F36 15A, 600V

Gen Set Module Breaker Options 1

C16 K1-A2/12.J2

K1-A1/12.K2

Byp C/10.J2 Byp B/10.J2

K1 A1

K1-13/12.D9

K2 A2

13

14

21

22

K2-A1/12.K5 K1-14/12.D8

2

GSM 1 Out A

3

4

GSM 1 Out B

5

6

GSM 1 Out C

40A, 480Vac

30uF, 400V

K2-53/12.D9

A1

1 A2

53

54

63

64

K2-A2/12.J5 K2-54/12.D8

Option 2

Q3

2

GSM 2 Out A

3

4

GSM 2 Out B

5

6

GSM 2 Out C

40A, 480Vac

1

4

3

6

5

CT2

L1-Out/4.J20

LSSW/4.J1

L2-Out/4.J20

1

4

3

6

5

H1

H2

CT3

LSSW/4.I1

L3-Out/4.I20

Out A

CT5 H1

D

System Out

H2

Out B

CT6 H1 X1

X1

H2 X2

H1

Input C

CT Ratio 1500:1 H2

X1

X1

H1

LSSW/4.J1

2

H2

Out C

X2

2

X2

32

CT4

H2

Input B

44

31

X1

X1

Input A

43

X2

CT1 H1

X2

Main Input

X2

D

CT Ratio 1500:1

E

Option 1

Q2

Blk Blk Blk

Gnd 1

3

2

F1, F2 ATQR, 4A, 4 600V

Wht

EMI EMI EMI PWA PWA PWA 242-7429 242-7429 242-7429 TVSS1

C

1

3

2

F3, F4 ATQR, 7A, 4 600V

In B/10.L2

Out C/10.H2

In A/10.L2

Out A/10.G2

EMI EMI EMI PWA PWA PWA 242-7429 242-7429 242-7429

C

MCB1-11/ 12.K12 MCB1

C2

MCB1-C2/ 10.D18

+24V +24V Rtn Rtn

1

1

Ib_1

2

2

Ia_1

2

1 Phs B

Phs A

Neut/Gnd

VCI 1 J1 Volts 1

2

1 2 3 4 5 6 7 8

24Vdc VCI 1 J6

Phs C

APC3 I/O VCI 1 J5

Ser Rx+ Ser Rx3 4 5 6 7 8 Vab1 Ser Tx+ Vab1 Ser TxVbc1 Ser Tx+ Vbc1 Ser TxVbn1 Ser Tx+ Vbn1 Ser TxMux Ser Tx+ Mux Ser Tx-

Phs B

VCI 1 J2 Volts 2

Neut/Gnd

Phs A

Phs C

1

1

2

1

2

VCI 1 435-9983

2

VCI 1 TB6

C1 1 3

4

Ic_1

5

6

B

T5 A N

C

VCI 1 TB1

VCI 1 TB2

VCI 1 TB3

Zigzag Xfmr

K5

B

95

K5-14/10.D19

B

K5-22/12.J12

1 2 3 4

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

K5-21/12.J13

97

96

VCI 1 TB5

Ic_2

MCB1-14/ 12.K12

98

VCI 1 TB4

Ib_2

14

ST

8 7 6 5 4 3 2 1

Ia_2

11

1

2

3

4

5

6

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

APC3 J9 VCI 1

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

VCI 1 24Vdc/ 11.L6

R1 25 ohms

Thermal Overload Relay

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 2 OF 17 6

5

4

3

2

1

6

5

4

3

2

1

F

F

SSS J2 Phase B

E

1 2 3 4 5 6 1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6

Components Installed with Local Bypass Option

SSS J3 Phase C SSS 420-5357

1 2 3 4 5 6

1 2 3 4 5 6

SSS J1 Phase A

E

K4 K4-A1/12.K8

A1

A2

13

14

23

24

1

2

THY 7

K4-A2/12.J8 3

1

4

5

2

6

K4-14/12.D9

7

K4-13/12.D9

THY 8

3

4

5

6

1

4

6

7

com

com

com

5

2

nc

nc

VCI 3 J2-1/ 15.K11 VCI 3 J2-3/ 15.J11 VCI 3 J2-6/ 15.K11

nc

3

D

D THY 9 F39

3 1

600V, 600A

4

5

1

1 2 3 4

K3 A1/12.B2

B4

A1

K3 B4/12.A2

A2

G K

G K

B'

C

C'

BYP SSD 420-5355

SSD J1 Serial I/O

1 2 3 4

2

G K

B

SSD J2 24Vdc

K3 Neut

Phs B

Phs A

VCI 3 J1 Volts 1

1

1

2

1

2

1

2

2

G K

A'

+24V +24V Rtn Rtn

APC3 I/O VCI 3 J7

Phs C

+24V +24V Rtn Rtn

G K

A

VCI 3 J4 AUX Ser Rx+ Ser Rx3 4 5 6 7 8 Vab1 Ser Tx+ Vab1 Ser TxVbc1 Ser Tx+ Vbc1 Ser TxVbn1 Ser Tx+ Vbn1 Ser TxMux Ser Tx+ Mux Ser Tx-

24Vdc VCI 3 J8

G K

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 Gate Pwr Status Gate Pwr Status rtn SS HS Temp+ SS HS Temp-

VCI 3 J2 Volts 2

C

1 +24Vdc +24Vdc +24Vdc +24Vdc +24Vdc +24Vdc Aux1 Aux2 Aux3 Aux4 Aux5 Aux6

Phs B

VCI 3 435-9983 Neut

Phs C

Phs A

1 2 3 4 5 6 7 8

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

6

2

7

F38

2

F37

SSD J2 HS Tmp

C

C1

C2

Shunt Pwr Rtn/ 12.E2

14

K3-11/12.D8

K3-14/12.D9

11

Byp SSD/ 12.E14

K3-24/12.D9

21 22

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

B

Byp SSD 24Vdc/11.K7

12 24

K3-21/12.D9

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

1 2 3 4 5 6 7 8

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

Shunt Pwr/ 12.D2

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

VCI_3 24Vdc/ 11.K9

ST

1 2 3 4

1 2 3 4

K3 A2/12.A2

B

APC3 J11 VCI 3

34

K3-31/15.K2

Byp A/2.M10 Byp B/2.M10 Byp C/2.L10

K3-34/15.J2

31 32 1

2

3

4

5

6

Out A/2.M12 Out B/2.M12 Out C/2.L12

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 3 OF 17 6

5

4

3

2

1

6

SSS J2 Phase B

3

2

1

F

SSS J3 Phase C 1 2 3 4 5 6

1 2 3 4 5 6

SSS 420-5357

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6

SSS J1 Phase A

4

1 2 3 4 5 6

F

5

THY1 2

E

L1 thms 1

THY2

4

5

1

1

4

1

2

E

L1tmp1/12.K18 L1tmp1/12.K18

L1 thms 2

5

2

3

4

L1tmp2/12.J18 L1tmp2/12.J18

L1 THY3 LSSW/2.H9

1

THY4

4

5

LSSW/2.H9

2

2

1

4

A2

B1

B2

C1

C2

L1-Out/2.H12 L2-Out/2.H12 L3-Out/2.H12

5

LSSW/2.H9

A1

119uH, 1200A

D

F7

THY5

THY6

4

D

L2 thms 1

F9

1

2

L2tmp1/12.K19 L2tmp1/12.K19

700VAC, 1250A

2

5

1

F8

J4

4

1

J5

L2 thms 2

J6

3

EMI PWA 259-3199 J1

5

2

J2

L2tmp2/12.J20 L2tmp2/12.J19

L2

J3

Rt1 HS Temp Phs B 2

A1

A2

UTL INV A/ 5.J3

B1

B2

UTL INV B/ 5.E3

C1

C2

1 2 3 4

1

4

UTL C/5.A3

43uH, 1000A

G K

G K

G K

G K

A'

B

B'

C

C'

+24V +24V Rtn Rtn

24Vdc SSD J2

1 2 3 4

1

G K

A

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 Gate Pwr Status Gate Pwr Status rtn SS HS Temp+ SS HS Temp-

G K

SSD J1 Serial I/O

C

2

1

2

1

2

1

2

1

2

1

2

C

SSD J2 HS Tmp

SSD 420-5355

A/C FILTER CAP BANK x10

AC-A/7.B1 AC-B/7.A1 AC-C/7.A1

45uF, 600VAC

45uF, 600VAC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

B

45uF, 600VAC

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

Line SSD 24Vdc/11.L12

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

1 2 3 4

B

APC3 J24 SSD

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 4 OF 17 6

5

4

3

2

1

6

5

4

3

2

1

F

F

UGD 420-5428

E

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

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

APC3 I/O Gate Hi+ Gate Lo+ Rx+ Tx1+ Tx2+ Amps Out Neut Jmp Bit 0 Jmp Bit 1 Jmp Gate HiGate LoRxTx1Tx2Amps rtn Neut Jmp rtn Bit 0 rtn Bit 1 rtn

+24V +24V Rtn Rtn

UGD-A J25 24Vdc In

UGD-A J2 Temp HS Temp Temp +

+24Vdc

UGD-A J3 -24Vdc LEM Sensor LEM In

UGD A 24Vdc/ 11.C15

1 2 3 4

1 2 3 4

1 2 3 4 5 6 7 8

HS therm

IGBT 2

IGBT 1 UGD-A J5

5

UGD-A J6

4

UGD-A J8

3

UGD-A J7 UGD-A J9

1

9

C89 C119 1.5uF, 1.5uF, 1200V 1200V 8

UGD-A J10

5

UGD-A J11

4

UGD-A J13

3

UGD-A J12 UGD-A J14

1

IGBT 3

9

C90 C120 1.5uF, 1.5uF, 1200V 1200V 8

UGD-A J15

5

UGD-A J16

4

UGD-A J18

3

UGD-A J17 UGD-A J19

1

UT INV A+/ 7.L21

IGBT 4

9

C91 C121 1.5uF, 1.5uF, 1200V 1200V 8

UGD-A J20

5

UGD-A J21

4

UGD-A J23

3

UGD-A J22 UGD-A J24

1

9

C92 C122 1.5uF, 1.5uF, 1200V 1200V 8

E CT7

2

2

10 1 2 3

2

10

2

10

10

(-)

UGD-A J1 Gnd UA Gate Hi+ UA Gate Lo+ UA Tx+ UA Rx1+ UA Rx2+ UA Amps+ Gnd UA Gate HiUA Gate LoUA TxUA Rx1UA Rx2UA Amps-

UT INV A-/ 7.K21

M (+)

APC3 J1 UGD A

5000:1 UTL INV A/ 4.G20

UGD 420-5428

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

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

APC3 I/O Gate Hi+ Gate Lo+ Rx+ Tx1+ Tx2+ Amps Out Neut Jmp Bit 0 Jmp Bit 1 Jmp Gate HiGate LoRxTx1Tx2Amps rtn Neut Jmp rtn Bit 0 rtn Bit 1 rtn

+24V +24V Rtn Rtn

UGD-B J25 24Vdc In

Temp -

UGD-B J2 HS Temp Temp +

+24Vdc -24Vdc

UGD-B J3 LEM Sensor

LEM In

UGD B 24Vdc/ 11.C14

1 2 3 4

1 2 3 4

1 2 3 4 5 6 7 8

C

HS therm

CT8

IGBT 5 UGD-B J5

5

UGD-B J6

4

UGD-B J8

3

UGD-B J7 UGD-B J9

IGBT 6

9

C93 C123 1.5uF, 1.5uF, 1200V 1200V 8

1

UGD-B J10

5

UGD-B J11

4

UGD-B J13

3

UGD-B J12 UGD-B J14

2

9

C94 C124 1.5uF, 1.5uF, 1200V 1200V 8

1

UGD-B J15

5

UGD-B J16

4

UGD-B J18

3

UGD-B J17 UGD-B J19

2

10 1 2 3

IGBT 7 9

C95 C125 1.5uF, 1.5uF, 1200V 1200V 8

1

UGD-B J20

5

UGD-B J21

4

UGD-B J23

3

UGD-B J22 UGD-B J24

2

10

UT INV B+/ 7.I21

IGBT 8

D

9

C96 C126 1.5uF, 1.5uF, 1200V 1200V 8

1 2

10

10

(-)

UGD-B J1 Gnd UB Gate Hi+ UB Gate Lo+ UB Tx+ UB Rx1+ UB Rx2+ UB Amps+ Gnd UB Gate HiUB Gate LoUB TxUB Rx1UB Rx2UB Amps-

UT INV B-/ 7.H21

M (+)

APC3 J2 UGD B

D

C

5000:1 UTL INV B/ 4.G20

UGD 420-5428

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

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

APC3 I/O Gate Hi+ Gate Lo+ Rx+ Tx1+ Tx2+ Amps Out Neut Jmp Bit 0 Jmp Bit 1 Jmp Gate HiGate LoRxTx1Tx2Amps rtn Neut Jmp rtn Bit 0 rtn Bit 1 rtn

+24V +24V Rtn Rtn

UGD-C J25 24Vdc In

UGD-C J2 Temp HS Temp Temp +

UGD C 24Vdc/ 11.C13

1 2 3 4

1 2 3 4

HS therm

IGBT 9 UGD-C J5

5

UGD-C J6

4

UGD-C J8

3

IGBT 10

9

C97 C127 1.5uF, 1.5uF, 1200V 1200V 8

UGD-C J10

5

UGD-C J11

4

UGD-C J13

3

IGBT 11

9

C98 C128 1.5uF, 1.5uF, 1200V 1200V 8

UGD-C J15

5

UGD-C J16

4

UGD-C J18

3

UT INV C+/ 7.F21

IGBT 12

9

C99 C129 1.5uF, 1.5uF, 1200V 1200V 8

UGD-C J20

5

UGD-C J21

4

UGD-C J23

3

9

C100

C130

1.5uF, 1.5uF, 1200V 1200V 8

B +24Vdc -24Vdc

UGD-C J3 LEM Sensor

LEM In

1 2 3 4 5 6 7 8

CT9

UGD-C J7 UGD-C J9

1

UGD-C J12 UGD-C J14

2 10

1 2 3

1

UGD-C J17 UGD-C J19

2 10

1

UGD-C J22 UGD-C J24

2

1 2

10

10

(-)

B

Gnd UC Gate Hi+ UC Gate Lo+ UC Tx+ UC Rx1+ UC Rx2+ UC Amps+ Gnd UC Gate HiUC Gate LoUC TxUC Rx1+ UC Rx2UC Amps-

UGD-C J1

UT INV C-/ 7.E21

M (+)

APC3 J3 UGD C

5000:1 UTL C/4.F20

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 5 OF 17 6

5

4

3

2

1

6

5

4

3

2

1

F

F APC3 J6 FGD A

APC3 I/O Gate1 Hi+ FGD-A J1 Gate1 Lo+ Gate2 Hi+ Gate2 Lo+ Rx+ Tx1+ Tx2+ Tx3+ B1 Amps Out B2 Amps Out Bit 0 Jmp Bit 1 Jmp B1 Gate HiB1 Gate LoB2 Gate HiB2 Gate LoRxTx1Tx2Tx3B1 Amps rtn B2 Amps rtn Bit 0 rtn Bit 1 rtn

FGD 420-5430 UGD-A J28 24Vdc In

+24V +24V Rtn Rtn

1 2 3 4

Temp -

1 2 3 4

UGD-A J11 HS Temp Temp +

+24Vdc -24Vdc FGD-A J3 +24Vdc LEM Sensor -24Vdc LEM 1 In LEM 2 In

FGD A 24Vdc/ 11.C11 IGBT 20

IGBT 19

HS therm

CT12 1 2 3

M

FGD-A J5

5

FGD-A J6

4

FGD-A J8

3

FGD-A J7 FGD-A J9

1

9

C107 C137 1.5uF, 1.5uF, 1200V 1200V 8

FGD-A J10

5

FGD-A J11

4

FGD-A J13

3

FGD-A J12 FGD-A J14

1

IGBT 21

9

C108 C138 1.5uF, 1.5uF, 1200V 1200V 8

FGD-A J15

5

FGD-A J16

4

FGD-A J18

3

FGD-A J17 FGD-A J19

1

FW INV A+/ 7.L10

IGBT 22

9

C109 C139 1.5uF, 1.5uF, 1200V 1200V 8

FGD-A J20

5

FGD-A J21

4

FGD-A J23

3

FGD-A J22 FGD-A J24

1

9

C110 C140 1.5uF, 1.5uF, 1200V 1200V 8

E

5000:1

1 2 3 4 5 6 7 8

2

2

10

CT13

2

10

2

10

10

(-)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3

FW INV A-/ 7.K10

M (+)

Shield

(-)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

(+)

E

Gnd FA Gate1 Hi+ FA Gate1 Lo+ FA Gate2 Hi+ FA Gate2 Lo+ FA Tx+ FA Rx1+ FA Rx2+ FA Rx3+ FA Amps1+ FA Amps2+ Gnd FA Gate1 HiFA Gate1 LoFA Gate2 HiFA Gate2 LoFA TxFA Rx1FA Rx2FA Rx3FA Amps1FA Amps2-

5000:1

Up Arm-A/8.L1 Lo Arm-A/8.D1 APC3 J7 FGD B APC3 I/O J1

Gate1 Hi+ FGD-B Gate1 Lo+ Gate2 Hi+ Gate2 Lo+ Rx+ Tx1+ Tx2+ Tx3+ B1 Amps Out B2 Amps Out Bit 0 Jmp Bit 1 Jmp B1 Gate HiB1 Gate LoB2 Gate HiB2 Gate LoRxTx1Tx2Tx3B1 Amps rtn B2 Amps rtn Bit 0 rtn Bit 1 rtn

FGD 420-5430 UGD-A J29 24Vdc In

+24V +24V Rtn Rtn

Temp -

UGD-A J12 HS Temp Temp +

+24Vdc -24Vdc FGD-A J4 +24Vdc LEM Sensor -24Vdc LEM 1 In LEM 2 In

FGD B 24Vdc/ 11.C10

1 2 3 4

1 2 3 4

IGBT 23

HS therm

CT14 1 2 3

M

FGD-B J5

5

FGD-B J6

4

FGD-B J8

3

IGBT 24

9

C111 C141 1.5uF, 1.5uF, 1200V 1200V 8

FGD-B J10

5

FGD-B J11

4

FGD-B J13

3

IGBT 25

9

C112 C142 1.5uF, 1.5uF, 1200V 1200V 8

FGD-B J15

5

FGD-B J16

4

FGD-B J18

3

FW INV B+/ 7.I10

IGBT 26

9

C113 C143 1.5uF, 1.5uF, 1200V 1200V 8

FGD-B J20

5

FGD-B J21

4

FGD-B J23

3

D

9

C114 C144 1.5uF, 1.5uF, 1200V 1200V 8

5000:1

1 2 3 4 5 6 7 8

FGD-B J7 UGD-B J9

1

FGD-B J12 FGD-B J14

2

1

10

CT15

FGD-B J17 FGD-B J19

2

1

FGD-B J22 FGD-B J24

2

10

1 2

10

10

(-)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3

FW INV B-/ 7.H10

M (+)

C

Shield

(-)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

(+)

D

Gnd FB Gate1 Hi+ FB Gate1 Lo+ FB Gate2 Hi+ FB Gate2 Lo+ FB Tx+ FB Rx1+ FB Rx2+ FB Rx3+ FB Amps1+ FB Amps2+ Gnd FB Gate1 HiFB Gate1 LoFB Gate2 HiFB Gate2 LoFB TxFB Rx1FB Rx2FB Rx3FB Amps1FB Amps2-

C

5000:1

Up Arm-B/8.L1 Lo Arm-B/8.D1 APC3 J8 FGD C APC3 I/O J1

Gate1 Hi+ FGD-C Gate1 Lo+ Gate2 Hi+ Gate2 Lo+ Rx+ Tx1+ Tx2+ Tx3+ B1 Amps Out B2 Amps Out Bit 0 Jmp Bit 1 Jmp B1 Gate HiB1 Gate LoB2 Gate HiB2 Gate LoRxTx1Tx2Tx3B1 Amps rtn B2 Amps rtn Bit 0 rtn Bit 1 rtn

FGD 420-5430 UGD-A J30 24Vdc In

+24V +24V Rtn Rtn

FGD C 24Vdc/ 11.C9

1 2 3 4

IGBT 27 FGD-C J5

Temp -

UGD-A J13 HS Temp Temp +

+24Vdc -24Vdc FGD-A J6 +24Vdc LEM Sensor -24Vdc LEM 1 In LEM 2 In

1 2 3 4

1 2 3 4 5 6 7 8

HS therm

CT16 1 2 3

M

5

FGD-C J6

4

FGD-C J8

3

IGBT 28

9

FGD-C J10

C115 C145 1.5uF, 1.5uF, 1200V 1200V 8

5

FGD-C J11

4

FGD-C J13

3

IGBT 29

9

FGD-C J15

C116 C146 1.5uF, 1.5uF, 1200V 1200V 8

5

FGD-C J16

4

FGD-C J18

3

FW INV C+/ 7.F10

IGBT 30

9

FGD-C J20

C117 C147 1.5uF, 1.5uF, 1200V 1200V 8

5

FGD-C J21

4

FGD-C J23

3

9

C118 C148 1.5uF, 1.5uF, 1200V 1200V 8

B

5000:1 FGD-C J7 FGD-C J9

FGD-C J12 FGD-C J14 10

CT17 1 2 3

1 2

1

FGD-C J17 FGD-C J19

2 10

1

FGD-C J22 FGD-C J24

2 10

1 2 10

(-)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

FW INV C-/ 7.E10

M (+)

Shield

(-)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

(+)

B

Gnd FC Gate1 Hi+ FC Gate1 Lo+ FC Gate2 Hi+ FC Gate2 Lo+ FC Tx+ FC Rx1+ FC Rx2+ FC Rx3+ FC Amps1+ FC Amps2+ Gnd FC Gate1 HiFC Gate1 LoFC Gate2 HiFC Gate2 LoFC TxFC Rx1FC Rx2FC Rx3FC Amps1FC Amps2-

5000:1

Up Arm-C/8.K1 Lo Arm-C/8.D1

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 6 OF 17 6

5

4

3

2

1

6

5

4

3

2

1

F

F 7Rt1

1

2

Thermistor

-

-

-

-

-

-

-

-

C72

C74 -

-

C11

C76

C78

-

-

R11 1.5K ohm, 5%, 225W

-

-

-

-

-

-

1 2 3 4 1 2 3 4

-

FC Gate Hi FC Gate Hi Rtn FC Gate Lo FC Gate Lo Rtn LC Gate Hi LC Gate Hi Rtn LC Gate Lo LC Gate Lo Rtn FC Amps Out Gnd LC Amps Out Gnd HS TempHS Temp+

UT INV A+/ 5.M21

+

E UT INV A-/ 5.J21

1

FCD TB3

2 3

C28

C30

UT INV B+/ 5.I21

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

C26

+

C24

+

C22

+

R5

C20

+

+

C18

+

C82

+

C80

+

C79

+

FW INV B+/ 6.I21

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

+24V +24V Rtn Rtn

C77

+

FW INV A-/ 6.J21

+

1 2 3 4

C75

-

C73

+

C12

+

C8

+

C6

+

C4

+

C2

2 3

C14

+

1.5K ohm, 5%, 225W

C10

+

R4

+

C9

+

+

+

+

FC-/8.G1

+

24Vdc FCD J7

C7

4700uF,450V x20

1

FCD TB2 DC Bus

C5

+

E

FCD J4 HS Temp

2 3

FC+/8.G1

+

FCD J1 Serial I/O

FCD TB1 Field Coil

C3

+

1

C1

+

FCD 435-9990

+

FW INV A+/ 6.M21

-

-

-

-

1.5K ohm, 5%, 225W

-

-

-

-

-

FCD 24Vdc/ 11.C6

4700uF, 450V x20

-

-

-

-

-

-

-

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

C29

D

C31

-

C27

-

C25

+

C23

+

R12 1.5K ohm, 5%, 225W

+

C21

+

+

C19

+

C17

+

-

FW INV B-/ 6.F21

C81

+

C13

APC3 J25 FCD

+

+

D

UT INV B-/ 5.F21

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

VCI 2 APC3 J10

-

-

-

-

-

-

-

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

-

C49

C51

UT INV C-/ 5.B21

-

-

-

-

-

-

-

Vab1 Ser Tx+ Vab1 Ser TxVbc1 Ser Tx+ Vbc1 Ser TxVbn1 Ser Tx+ Vbn1 Ser TxMux Ser Tx+ Mux Ser Tx-

-

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

C47

-

C45

-

C66

C68

C70

-

-

C64

+

-

C62

+

-

R7 1.5K ohm, 5%, 225W

+

C60

+

+

-

C58

+

-

C56

+

-

C54

-

-

-

B

4700uF,450V x20

-

-

-

-

-

-

-

1 2 3 4 5 6 7 8

C67

C69

C71

-

C65

+

C63

+

R14 1.5K ohm, 5%, 225W

+

C61

+

+

C59

+

C57

+

C55

+

-

AC-A/4.E18

+

+ C53

-

Ser Rx+ Ser Rx3 4 5 6 7 8

-

1 2 3 4

UT INV C+/ 5.D21

+

+24V +24V Rtn Rtn

C50

+

1.5K ohm, 5%, 225W

C43

+

R13

C41

+

+

C39

+

+

C37

+

+

C52

DC-

DC+

Phs B

Neut/Gnd

Phs C

Phs A

VCI 2 435-9983

+

Volts 2 VCI 2 J2

1 2 3 4 5 6 7 8

C48

-

C46

+

C44

+

1.5K ohm, 5%, 225W

C42

+

R6

C40

+

+

+

+

C35

+

+

+

Volts 1 VCI 2 J1

B

C38

C

C33

FW INV C-/ 6.B21

VCI 2 J5 APC3 I/O

C36

4700uF,450V x20

C

VCI 2 J6 24Vdc

C34

+

C32

+

+

FW INV C+/ 6.D21 VCI 2 24Vdc/ 11.K13

AC-C/4.E18 AC-B/4.E18

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 7 OF 17 6

5

4

3

2

1

6

5

F

4

3

2

1

Vacuum Gauge

Internal Flywheel Wiring

F FWI J4 Vacuum

Upper Armature

Red Ind. Accel

A

Up Arm-B/6.E3

+ +

B

-

Up Arm-A/6.J3

C

Up Arm-C/6.A3

1 2 3 4

Black

1 2 3 4

APC3 J26 FWI

FWI J5 Ind. Accel.

FWI J2 APC3 I/O

FWI J6 Upper FW

Load Cell

E

Red Blk Grn Wht

Upper BrngTmp 1 Upper BrngTmp 2

Upper Arm Tmp 1 Upper ArmTmp 2

1 4 2 5 6 3

1 4 2 5 6 3

1 3 2 4

1 3 2 4

1 3 2 4

1 3 2 4

1 6 2 7 8 4 9 5 10 3

1 6 2 7 8 4 9 5 10 3

1 3 2 4

1 3 2 4

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

Iso +10Vdc Iso Gnd Load Cell+ Load Cell Upr Brng Tmp1+ Iso Gnd Upr Brng Tmp2+ Iso Gnd Upr Arm Tmp1+ Iso Gnd Upr Arm Tmp2+ Iso Gnd Upr Spr Tmp1+ Iso Gnd Upr Spr Tmp2+ Iso Gnd

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

FWI Tx+ FWI Tx3 4 5 6 7 8 9 10

E

FWI 24Vdc/ 11.C7 FWI J10 24Vdc

+24V +24V Rtn Rtn

1 2 3 4

D

D

FWI J7 Radial FW Field Coil Tmp 1

FC (+)

FC+/7.L7

Field Coil Tmp 2

1 3 2 4

1 3 2 4

1 3 2 4

1 3 2 4

1 5 2 6 3 7 4 8

1 3 2 4

1 3 2 4

1 3 2 4

1 3 2 4

1 3 2 4

1 3 2 4

1 3 2 4

1 3 2 4

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

FC (-)

FC-/7.K7

Rad FC Tmp1+ Iso Gnd Rad FC Tmp2+ Iso Gnd Rad Spr Tmp1+ Iso Gnd Rad Spr Tmp2+ Iso Gnd

FWI 435-9984

FWI J8 Lower FW

C Lower BrngTmp 1 Lower BrngTmp 2

Lower Armature Lower Arm Tmp 1

A

Lo Arm-B/6.E3

+ +

B

-

Lo Arm-A/6.J3

C

Lo Arm-C/6.A3

Lower ArmTmp 2

C

Lwr Brng Tmp1+ Iso Gnd Lwr Brng Tmp2+ Iso Gnd Lwr Arm Tmp1+ Iso Gnd Lwr Arm Tmp2+ Iso Gnd Lwr Spr Tmp1+ Iso Gnd Lwr Spr Tmp2+ Iso Gnd

B

B RPS J1

Speed Sensor

vcumL1/ 10.B10

Vcm2

vcumL2/ 10.B10

1

L1

2

L2

3

Gnd

1 3 2 4

Vacuum Pump

1 3 2 4

1 3 2 4

RPS J2 1 3 2 4

1 2 3 4 5 6

FWI J3 RPS 1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6

vc gnd/10.B10 435-9965

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 8 OF 17 6

5

4

3

2

1

1 2 3 4 5 6 7 8 9 10

6 FNI J2 Fan2 FNI J3 Fan3

5 FNI J4 Fan4

4

FNI J5 Fan5

FAN 435-9978

1 2 3 4 6 7 8 9 5 10

20Vdc Status 0-10V Fan Cntrl Analog Fan GND Status Rtn GND GND PE PE

FNI J6 Fan6 FNI J7 Fan7 FI J13 APC3 I/O

3

KL1-1

KL1-2

KL1-3

6

6

4 5

4 5

3

3

1 2

1 2

F31, F32, F33 600V, 3A 1 3 5

2 4 6

FNI J8 Fan8 FNI J9 Fan9

1 2 3 4 6 7 8 9 5 10

L3

L2

L1

24

23

22

21

30

29

28

27

26

14

13

12

11

20

19

18

17

16

4

3

2

1

10

9

8

7

6

3

20Vdc Status 0-10V Fan Cntrl Analog Fan GND Status Rtn GND GND PE PE

KL3-2 KL3-8

Fan7

KL2-2

KL2-3

6

KL3-3 KL3-1

KL3-5

5

COM GND GND

+20V NO 0-10V OUT

6

6

4 5

4

4

5

F28, F29, F30 600V, 3A

Shield

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

KL1-1

1 2 3

1 2 3

2

L3

KL1-2

KL1-3

3

KL3-2 KL3-8

Fan6

L2

L1

6

KL2-2

KL2-3

1

KL3-3 KL3-1

KL3-5

5

COM GND GND

+20V NO 0-10V OUT

6

6

4 5

4

4

5

F25, F26, F27 600V, 3A

Shield

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

KL1-1

1 2 3

1 2 3

2

L3

KL1-2

KL1-3

3

KL3-2 KL3-8

Fan5

L2

L1

6

KL2-2

KL2-3

1

KL3-3 KL3-1

KL3-5

5

COM GND GND

+20V NO 0-10V OUT

6

6

4 5

4 5

4

Shield

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

KL1-1

1 2 3

1 2 3

F22, F23, F24 600V, 3A

1 2 3 4 6 7 8 9 5 10

1 2 3 4 6 7 8 9 5 10

20Vdc Status 0-10V Fan Cntrl Analog Fan GND Status Rtn GND GND PE PE

L3

KL1-2

KL1-3

3

KL3-2 KL3-8

Fan4

L2

L1

2

KL2-2

KL2-3

6

KL3-3 KL3-1

KL3-5

1

COM GND GND

+20V NO 0-10V OUT

5

Shield

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

6

6

4 5

4

4

5

F19, F20, F21 600V, 3A 25

20Vdc Status 0-10V Fan Cntrl Analog Fan GND Status Rtn GND GND PE PE

1 2 3 4 6 7 8 9 5 10

20Vdc Status 0-10V Fan Cntrl Analog Fan GND Status Rtn GND GND PE PE

KL1-1

3

KL3-2 KL3-8

L3

1 2 3

1 2 3

2

KL2-2

Fan3

KL1-2

KL1-3

6

L2

L1

1

COM GND GND

KL2-3

5

KL3-3 KL3-1

KL3-5

6

6

4 5

4 5

4

+20V NO 0-10V OUT

KL1-1

3

3

1 2

1 2

3

Shield

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

L3

KL1-2

KL1-3

F16, F17, F18 600V, 3A 15

1 2 3 4 6 7 8 9 5 10

1 2 3 4 6 7 8 9 5 10

20Vdc Status 0-10V Fan Cntrl Analog Fan GND Status Rtn GND GND PE PE

KL3-2 KL3-8

Fan2 L2

L1

2

KL2-2

KL2-3

6

KL3-3 KL3-1

KL3-5

1

COM GND GND

+20V NO 0-10V OUT

6

6

4 5

4 5

4

Shield

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

KL1-1

5

5

20Vdc Status 0-10V Fan Cntrl Analog Fan GND Status Rtn GND GND PE PE

1 2 3 4 6 7 8 9 5 10

20Vdc Status 0-10V Fan Cntrl Analog Fan GND Status Rtn GND GND PE PE

L3

3

KL3-2 KL3-8

KL2-2

3

3

1 2

1 2

2

COM GND GND

Fan1 KL1-2

KL1-3

6

L2

L1

1

KL3-3 KL3-1

KL2-3

F13, F14, F15 600V, 3A Fan TB-25/ 2.L21

+24V +24V Rtn Rtn

FNI J1 Fan1 KL3-5

6

6

4 5

4 5

3

3

1 2

1 2 4

+20V NO 0-10V OUT

KL1-1

KL1-2

KL1-3

5

4

Ser Rx+ Ser Rx3 4 5 6 7 8 Ser Tx+ Ser Tx-

B L3

L2

L1

F10, F11, F12 600V, 3A

Shield

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

KL2-2

KL2-3 3

KL3-2 KL3-8

KL3-3 KL3-1

KL3-5

2

COM GND GND

+20V NO 0-10V OUT

1

5

1 2 3 4

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

1 2 3 4 6 7 8 9 5 10

20Vdc Status 0-10V Fan Cntrl Analog Fan GND Status Rtn GND GND PE PE

Shield

1 2 3 4 5 6 7 8

C 1 2 3 4 5 6 7 8

D

1 2 3 4 6 7 8 9 5 10

E

20Vdc Status 0-10V Fan Cntrl Analog Fan GND Status Rtn GND GND PE PE

6 2

2

1

F F

Fan TB-15/ 2.M21

Fan TB-5 / 2.M21

E

Fan8

D

C

24Vdc FI J11 FNI J10 Fan10

B

FAN 24Vdc/ 11.C16

APC3 J18 FAN

A A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 9 OF 17 1

6

5

4

3

1

2

F

F

480V(H5)

In B/2.F8

T1

1

415V(H4)

230Vac

2 (X2)160V

400V(H3)

PDAC 420-5358

TB1 (X3)230V

160Vac

3

Com

380V(H2)

PDAC J1 K1 230V

rtn rtn 230V 230V

1 2 3 4

PDAC J2 K1 160V

rtn rtn 160V 160V

1 2 3 4

rtn rtn

1 2 3 4

H1-B

In A/2.F8

H1-A (X1)Com

H1

*Note: Install jumper wire harness between TB1 and TB2 for single input systems

multi-tap xfmr

thrm1 Thermistor

E 480V(H5)

Byp C/2.J5

T2

K1 160V SRC/ 12.L2

E

TB2

(X3)230V

1

415V(H4)

230Vac

2 (X2)160V

400V(H3)

K1 160V SRC Rtn/12.K2

160Vac

3

PDAC J3 230V K3 230V MO 230V

Com

380V(H2)

K3 230V MO SRC Rtn/ 12.D2

K3 230V MO SRC/12.C2

H1-B

Byp B/2.J5

H1-A (X1)Com

H1

multi-tap xfmr

thrm3 Thermistor

rtn rtn

FUSE F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16

T2 optional / Used with dual input system

D 480V(H5)

Out C/2.F14

T3

TB3 (X3)230V

1

415V(H4) 400V(H3)

230Vac

2 (X2)160V

160Vac

3

Com

380V(H2) H1-B

Out A/2.F14

H1-A H1

thrm2 Thermistor

(X1)Com

multi-tap xfmr

CAT Part # 180-6255 420-5358 180-6255 180-6255 180-6255 420-5358 420-5358 180-6255 180-6255 420-5358 420-5358 180-6214 180-6214

DESCRIPTION K1 230V K1 160V T1 160V rect K3 230V MO K3 230V CC K4 230V K4 160V T2 160V rect 20V Vacuum pump K2 230V spare (3W ZZ shunt tip) K2 160V T3 160V rect T4 160V rect PS1 feed PS2 feed

RATING none 3A, 250V 10A, 250V 3A, 250V 3A, 250V 3A, 250V none 10A, 250V 10A, 250V 3A, 250V 3A, 250V none 10A, 250V 10A, 250V 10A, 500Vdc 10A, 500Vdc

TYPE

1

TRM10 TRM10 TRM3 TRM3 TRM10 TRM10 ATM10 ATM10

PDAC J6 K4 160V

rtn rtn 160V 160V

1 2 3 4

PDAC J7 K2 230V

rtn rtn 230V 230V

1 2 3 4

D

K4 230V SRC Rtn/12.K8 K4 230V SRC/ 12.L8

K2 230V SRC Rtn/12.K5 K2 230V SRC/ 12.L5

C

15Vdc AC PS1 stat AC PS2 stat AC PS3 stat AC PS4 stat 15Vdc rtn AC PS1 stat rtn AC PS2 stat rtn AC PS3 stat rtn AC PS4 stat rtn

PDAC J11 PS2 220Vdc rtn rtn 220Vdc 220Vdc

rtn rtn 220Vdc 220Vdc

PDAC J10 PS1 220Vdc

rtn rtn 160V 160V

1 2 3 4

PDAC J8 Out Spare

rtn rtn 230V 230V

1 2 3 4

MCB1-C2/ 2.E21 K5-14/2.C21

B

1 2 3 4 5 6 7 8 9 10

1 2 3 4

1 2 3 4

1

gnd

Gnd

gnd

Comm

230Vac

TB6 VACUUM

PDAC J9 K2 160V

3

gnd

2

TB5

B

1 2 3 4

K3 230V CLS SRC/12.B2

Com

PDAC J12 AC PS Status

3

rtn rtn 230V 230V

K3 230V CLS SRC Rtn/ 12.C2

160Vac

3

1

PDAC J5 K4 230V

230Vac

2

2

1 2 3 4

TRM3 TRM10 TRM3 TRM3 TRM3

TB4

C

PDAC J4 230V K3 230V CC 230V

PS2 in+/11.F2

PS2 in-/11.F2

PS1 in+/11.I2

PS1 in-/11.I2

vcumL1/8.B1 vc gnd/8.A1 vcumL2/8.B1

AC PS Stat/ 12.E10

A

A

THIS SCHEMATIC IS FOR THE FLYWEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 10 OF 17 6

5

4

3

2

1

6

5

4

3

2

1

F

F

VCI 1 24Vdc/ 2.A8 Byp SSD 24Vdc/3.D14

1 2 3 4

1 2 3 4

1 2 3 4

1 2 3 4

1 2 3 4

1 2 3 4

1 2 3 4

+24V +24V Rtn Rtn

+24V +24V Rtn Rtn

+24V +24V Rtn Rtn

+24V +24V Rtn Rtn

+24V +24V Rtn Rtn

+24V +24V Rtn Rtn

+24V +24V Rtn Rtn

VCI 2 24Vdc/ 7.F1

1 2 3 4

PS1-14/12.K11 PS1-13/12.K11

CIO 24Vdc/ 14.C3

VCI_3 24Vdc/ 3.D1

+24V +24V Rtn Rtn

E

Line SSD 24Vdc/4.C3

APC3 24Vdc/ 13.J19

BCI 24Vdc/ 12.E21

E

+24V +24V Rtn Rtn

+24V +24V Rtn Rtn

-

+24V +24V Rtn Rtn

-

+24V +24V Rtn Rtn

24Vdc ps L N Gnd + +

+24V +24V Rtn Rtn

ok

+24V +24V Rtn Rtn

13 14 DC

I<In

PS1

J10

J11

J12

J13

J14

J1

PS1 in+/ 10.B12 PS1 in-/10.B11

J2

J3

J4

J5

J6

J9

J8

J7

1 2

TB1

3

D

D FUSE F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14

PS2-14/12.J11 PS2-13/12.J11

-

FUSE F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28

PDDC 420-5352

CAT Part # DESCRIPTION 279-5201 FCD 279-5201 FWI 279-5201 UGD N2 279-5201 FGD C 279-5201 FGD B 279-5201 FGD A 279-5201 UGD N1 279-5201 UGD C 279-5201 UGD B 279-5201 UGD A 279-5201 FAN spare spare spare

RATING 3A, 32Vdc 3A, 32Vdc 5A, 32Vdc 3A, 32Vdc 3A, 32Vdc 53A, 32Vdc 3A, 32Vdc 3A, 32Vdc 3A, 32Vdc 3A, 32Vdc 3A, 32Vdc none none none

TYPE ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A

C

1

TB2

J28 +24V +24V Rtn Rtn

J27 +24V +24V Rtn Rtn

J26 +24V +24V Rtn Rtn

+24V +24V Rtn Rtn

J25

1 2 3 4

J24 +24V +24V Rtn Rtn

J23

1 2 3 4

J22

+24V +24V Rtn Rtn

J21

1 2 3 4

J20

+24V +24V Rtn Rtn

J19

1 2 3 4

J18

+24V +24V Rtn Rtn

+24V +24V Rtn Rtn 1 2 3 4

J17

+24V +24V Rtn Rtn

+24V +24V Rtn Rtn

J16

1 2 3 4

J15

1 2 3 4

2 3

+24V +24V Rtn Rtn

PS2 in+/ 10.B13 PS2 in-/10.B12

-

1 2 3 4

C

-

+24V +24V Rtn Rtn

L N Gnd + +

TYPE ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A ATO 3A

+24V +24V Rtn Rtn

ok

24Vdc ps

RATING 3A, 32Vdc 3A, 32Vdc 5A, 32Vdc 3A, 32Vdc 3A, 32Vdc 53A, 32Vdc 3A, 32Vdc 3A, 32Vdc 3A, 32Vdc 3A, 32Vdc 3A, 32Vdc 3A, 32Vdc none none

1 2 3 4

13 14 DC

I<In

PS2

CAT Part # DESCRIPTION 279-5201 VCI-1 279-5201 Byp SSD 438-0341 BCI 279-5201 VCI-3 279-5201 APC3 438-0341 CIO 279-5201 Line SSD 279-5201 VCI-2 279-5201 ISN 1 279-5201 ISN 2 279-5201 ISN 3 279-5201 ISN 4 spare spare

B

B FGD B 24Vdc/ 6.I8

FCD 24Vdc/ 7.I2 FWI 24Vdc/ 8.I21

FGD C 24Vdc/ 6.D8

FAN 24Vdc/ 9.A20

UGD B 24Vdc/ 5.I8 FGD A 24Vdc/ 6.M8

UGD C 24Vdc/ 5.D8

UGD A 24Vdc/ 5.M8

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 11 OF 17 6

5

4

3

2

1

Shunt Pwr Rtn/ 3.D10

Shunt Pwr/ 3.D9

6

K3 230V MO SRC Rtn/ 10.J18 K3 230V MO SRC/10.J19

B

5 1 2 3 4 5 6 7 8 9 10

*Note: Wire harness connection point is user selectable between BCI J3 and J3' depending on application.

4 Serial Rx+ Serial Rx3 4 5 6 7 8 Serial Tx+ Serial Tx1 2 3 4 5 6 7 8 9 10

BCI J6 DC PS Status

BCI J10 AC PS Status

BCI J7 ZZ Status

AC PS Stat/ 10.B15

3

BCI J8 GSM Status

BCI J11 Bypass SSD

Byp SSD/ 3.D18

BCI J9 Spare Status BCI J13 Neut Ind tmps

BCI J18 REPO Buttons

C

BCI J14 Spare Temp

A B

NO NO

C

2

L2 tmp1 L2 tmp2 L2 tmp1 rtn L2 tmp2 rtn

L1 tmp1 L1 tmp2 L1 tmp1 rtn L1 tmp2 rtn

Temp 2 Temp rtn 4

1 2 3 4

+24Vdc +24Vdc Spare1 Spare2

1 2 3 4

1 2 3 4

BCI J15 Line Ind tmps

BCI J19 EPO Button BCI J12 Serial I/O

L2tmp2/4.H19

L2tmp2/4.H19

L1tmp2/4.K12

L1tmp2/4.J12

K5-21/2.B19

K5-22/2.B21

L2tmp1/4.H19

L2tmp1/4.H19

L1tmp1/4.K12

L1tmp1/4.K12

MCB1-11/ 2.F21

MCB1-14/ 2.E21

PS1-13/11.K2

3

+24V +24V Rtn Rtn

+24Vdc rtn rtn Harness ok gnd gnd 1 2 3 4 5 6

BCI J5 AUX

1 2 3 4

BCI J4 K4

+24Vdc +24Vdc GSM1 GSM2

BCI J2 K2

PS2-13/11.G2

4

1 2 3 4

+24Vdc CR4 rtn CR4 rtn CR5 rtn CR5 rtn Harness ok Gnd Gnd Gnd Gnd 1 2 3 4 5 6 7 8 9 10

BCI J3' K3 NC

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 SSD PS fault SSD PS Fault HS tmp HS tmp rtn

K4-A2/3.K10

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

K2-A2/2.J13

1 2 3 4

K1-A2/2.J9

+24Vdc +24Vdc ZZ1 ZZ2

K4 230V SRC Rtn/10.H18

PS1-14/11.K2

K2 230V SRC Rtn/10.F18 PS2-14/11.H2

K1 160V SRC Rtn/10.K18

1 2 3 4

K4-A1/3.K8

+24Vdc +24Vdc PS1 PS2

K2-A1/2.J12

+15Vdc AC PS1 AC PS2 AC PS3 AC PS4 Gnd Gnd Gnd Gnd Gnd

K1-A1/2.J8

1 2 3 4 5 6 7 8 9 10

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

K4 DCK4 DCK4 DCK4 RTN K4 RTN K4 RTN K4 RTN K4 DC+ K4 DC+ K4 DC+ K4 SRC NO K4 SRC NO K4 SRC NC K4 SRC NC

K4 230V SRC/ 10.H19

+24Vdc +24Vdc +24Vdc +24Vdc +24Vdc K1 Status K2 Status K3 Status 1 K3 Status 2 K4 Status

K2 230V SRC/ 10.F19

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 K2 DCK2 DCK2 DCK2 RTN K2 RTN K2 RTN K2 RTN K2 DC+ K2 DC+ K2 DC+ K2 SRC NO K2 SRC NO K2 SRC NC K2 SRC NC

5

1 2 3 4 5 6 7 8 9 10

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

BCI J1 K1

K1 DCK1 DCK1 DCK1 RTN K1 RTN K1 RTN K1 RTN K1 DC+ K1 DC+ K1 DC+ K1 SRC NO K1 SRC NO K1 SRC NC K1 SRC NC

K1 160V SRC/ 10.K19

K1-13/2.I8 K2-53/2.I12 K3-14/3.D10 K3-24/3.C10 K4-13/3.J8

BCI J3 K3 NO

K1-14/2.I9 K2-54/2.I13 K3-11/3.D9 K3-21/3.C9 K4-14/3.J10

D

NC cmd stat in Gnd Gnd Not Used K3 Rtn K3 Rtn K3 Rtn K3 Rtn NC cmd stat out Shunt Pwr Shunt Pwr Not Used NC Close Cmd K3 Close Src K3 Motor Op Src K3 Motor Op Src

NO cmd stat in Gnd Gnd Not Used K3 RTN K3 RTN K3 RTN K3 RTN NO cmd stat out Shunt Pwr Shunt Pwr Not Used NO Close CMD K3 Close Src K3 Motor Op Src K3 Motor Op Src

E

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

6 2 1

F F

E

BCI J16 Filter Ind tmps

D

BCI 420-5356 24Vdc BCI J17

BCI 24Vdc/ 11.L8

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 12 OF 17 1

C

repo/14.I16

EPO PB1 APC3 J19 BCI

K3 230V CLS SRC Rtn/ 10.I18 K3 230V CLS SRC/10.I19

B

K3 B4/3.E10 K3 A1/3.E9

K3 A2/3.E10

A

6

5

4

3

2

1

F

F

See other schematic pages for APC3 to PWA connections.

E

APC3 J20

APC3 J21

1 2 3 4 5 6 7 8 9 10

Spare 1

APC3 J22

1 2 3 4 5 6 7 8 9 10

Spare 2

E

APC3 J23

1 2 3 4 5 6 7 8 9 10

APC3 J29

1 2 3 4 5 6 7 8 9 10

Spare 3

Service Port

APC3 24Vdc/ 11.L10

Spare 4

APC3 J31 24Vdc

D

APC3 J4

APC3 J5

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

C

UGD N1

APC3 J14

APC3 J13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

UGD N2

APC3 J15

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

ISN 1 Pri

ISN 1 Red

APC3 J16

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

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

ISN 2 Pri

1 2 3 4

1 2 3 4

D

APC3 J12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

C

VCI 4

ISN 2 Red

B

B

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 13 OF 17 6

5

4

3

2

1

1 2 3 4 5 6 7 8 9 10

6

B

5 4 4

3

4

2

1

6

5

4

Gnd

Gnd

Gnd

NC REPO

NO REPO

NO REPO

SELV 24Vdc CIO J15

3

CIO J16 CIO Ethernet

2

Iso Gnd

Iso Gnd

Iso +24Vdc

Iso +24Vdc

Shield

1 NO NO NC NC 6 Gnd Gnd Gnd Gnd

1 24Vdc 3 rtn

1 2 3 4 5 6 7 8 9 10

1 2 3 4

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

Gnd

Rtn

1 2 3 4 5 6 7 8 9

+24Vdc

3

4

3

2

Tx Gnd

Remote Status CIO J14

1

4

3

24Vdc

CIO J13 RS485

2

Shield

Rx-

Rx+

CIO J12 Modem 24Vdc

1

6

5

Gnd

Tx-

Tx+

Outputs CIO J10

3

Out 8 com Out 8 NC

CIO J11 Modem

2

1

24

Out 7 NC Out 8 NO

1 2 3 4 5 6 7 8 9

1 Tx Rx 4 Iso gnd 6 7 8 9

1 2 3 4

4

23

Out 7 com

Out 7 NO

Out 6 NC

Out 6 com

Out 6 NO

Out 5 NC

Out 5 com

Out 5 NO

Out 4 NC

CIO J7 Disp. Ethernet

22

21

20

19

18

17

16

15

14

13

Inputs CIO J8

Out 4 com

Out 4 NO

Out 3 NC

CIO J6 Display

12

11

10

Out 3 com

Out 3 NO

Out 2 NC

CIO J5 Display I/O

9

8

7

Out 2 com

Out 2 NO

Out 1 NC

C

6

5

Out 1 com

Out 1 NO

Serial I/O CIO J1

3

In 8

In 7

In 6

CIO J4 Display Power

2

In 4 In 5

+24V 2 Rtn 4

5

1

16

15

14

13

CIO J3 KS / HS

In 3

D

11

PB1 Horn Silence

12

Iso +24Vdc In 1

14

In 2

k

10

k

8

k

9

A2

MBP TB-4 ESS TB-5

13

6

a

7

a

4

a

5

3 4 5

A1

3

1

CIO J2 LED/Horn

2

24Vdc CIO J18 KSW 1

MBP TB-3

1 2 3 4 5 6

24Vdc 24Vdc 24Vdc KS KS HS

1 8 7

LED3 Red

ESS TB-4

uP Rx+ uP RxPLD Rx+ PLD Rx5 6 PLD Tx+ PLD TxuP Tx+ uP Tx-

1 2 3 4 5 6 7 8 9 10

LED2 Yel

1 2 3 4 5 6 7 8 9 10

CIO 24Vdc/ 11.K11 1 2 3 4 5 6 7 8

LED1 Grn

24Vdc 24Vdc 24Vdc 24Vdc Horn Led Grn Led Yel Led Red

H1 Horn

+24V +24V Rtn Rtn

E

1 2 3 4

6 2 1

F F

Display

Comm1 Display I/O

E

repo/12.E16

D

CIO J19 BCI REPO

CIO 420-5442

C

CIO J20 REPO

B

ESS/15.L11

MBP/15.K2

Wired if options installed

APC3 J17 CIO

A A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 14 OF 17 1

6

5

4

3

2

1

F

F

E

MBP Interface

E

ESS Option ESS/14.C9 F40, F41, F42

MBP/14.C9 VCI 3 J2-1/3.I3 D

K3-31/3.B9

VCI 3 J2-6/3.I3

K3-34/3.C10

VCI 3 J2-3/3.I3

1

2

3

4

5

6

D

600V, 1A 3 4

1 2

3 4

C

1 2 3

4 5

1 2 3

4 5

ESS TB1

MBP TB1

1 2

C

External Source Sync: ESS TB1-1 Phase A ESS TB1-2 Phase B ESS TB1-3 Phase C ESS TB 1-4 Sync ESS TB1-5 Sync

Customer Connection: MBP TB1-1 Bypass Status MBP TB1-2 Bypass Status Rtn MBP TB 1-3 Xfer Inhibit MBP TB1-4 Xfer Inhibit Rtn

B

B

A

A

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 SCHEMATIC PART NUMBER: 438-0387, CHANGE: 00 SHEET 15 OF 17 6

5

4

3

2

1

6

F

4

5

3

CONVERTER AS 420-5426

CONVERTER AS 420-5425

1

2

CAPACITOR AS 420-5418 (x4)

F

TRANSDUCER 420-5403 (x11)

BUSS AS 420-5451

E

BLOCK AS 420-5431

E

FAN AS 420-5423 (x8)

CONTROL AS 420-5434

BOARD AS FWI 435-9984

D

FRONT VIEW

FPU CABINET ASSEMBLY

D

REAR VIEW

C

C

BOARD AS FAN 435-9978 FAN AS 420-5423 (x8)

FLYWHEEL AS 420-5422

B

FRONT VIEW

A

6

5

B

REAR VIEW

4

3

THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 (FPU CABINET ASSEMBLY) SCHEMATIC PART NUMBER: 436-0004, CHANGE: 00 SHEET 16 OF 17 2

1

A

1

2

S10 CABINET ASSEMBLY

F

FUSE 201-7590 (x3) & SWITCH 203-3869 (x3)

BOARD AS VCI 435-9983

TRANSFORMER 250-3466 (x5)

BOARD AS PDAC 420-5358

SWITCH 420-5369

INSULATOR 420-5365 (x2)

INSULATOR 420-5370 (x33)

E

BOARD AS PDDC 420-5352 BOARD AS 438-0340 (x3)

SUPPRESOR 420-5368

BOARD AS VC1 420-5353

D

BOARD AS 242-7429 (x12)

D

CONTACTOR 420-5363

BOARD AS VC1 420-5353

CONTROL AS 438-0363

POWER SUPPLY 420-5499 (x2)

C

BOARD AS SSS 420-5357 (x2)

CAPACITOR 240-0811

ANTENNA 435-9973

CONTACTOR 435-9972 E

F

BOARD AS APC3 420-5354

BOARD AS SSD 420-5355 (x2)

INDUCTOR 438-0364

C

TRANSFORMER 420-5390

INSULATOR 420-5436 (x2) BOARD AS C10 420-5442

B

FUSE BLOCK 279-6652 (x3)

TRANSFORMER 435-9976

FUSE 420-5389 (x3)

B

INSULATOR 420-5400 (x3) CAPACITOR AS 438-0350 (x2)

A

BOARD AS BCI 420-5356

6

FRONT VIEW

RIGHT SIDE VIEW

BOARD AS EMI 259-3199

MODULE THYRISTOR 328-3016 (x3)

CONTACTOR 420-5364

REAR VIEW THIS SCHEMATIC IS FOR THE FLYWHEEL 750, 3-WIRE ELECTRICAL SYSTEM MEDIA NUMBER: UENR3955 (S10 CABINET ASSEMBLY) SCHEMATIC PART NUMBER: 436-0003, CHANGE: 00 SHEET 17 OF 17

5

4

3

2

1

A