The vacuum pump is internally configured for 240 VAC operation. Use the following steps to operate the vacuum pump prior to energizing the UPS.
Note: Changing the configuration of the vacuum pump for 120 VAC operation will void the warranty of the pump.
- Temporarily disconnect the 240 VAC internal wiring to the receptacle on the right side of the pump.
- Connect a 240 VAC line cord from an external source to operate the vacuum pump.
- Once finished operating the vacuum pump, ensure that the external 240 VAC source has been disconnected.
- Reconnect the internal 240 VAC wiring to the receptacle for the vacuum pump prior to energizing the input terminal of the UPS.
Note: The vacuum pump has a tamper proof label. The tamper proof label prohibits the service technician from changing the configuration of the pump for 120 VAC operation. 120 VAC must not be used as the source voltage for the process of vacuum draw on the flywheel during the commissioning procedure. A tamper proof label that is corrupted will void any warranty claim that is associated with the vacuum pump.
The following list of procedures is not shown in order of importance. Each procedure must be done.
- Do not run the vacuum pump when the bearing re-loaders are changed in order to install bearings. The vacuum pump could circulate contaminants from the outside air into the system.
- When the bearing re-loaders are changed in order to install bearings, complete the procedure in a timely manner to minimize the risk of contamination.
- Perform a thorough inspection of the vacuum lines and connection points. Look for any possible discrepancies that could result in a vacuum leak.
- To ensure that the vacuum pump oil is clean, change the oil. Contaminants in the oil will extend the time that is required to draw a vacuum. Dirty oil may also prevent a vacuum from being drawn at all.
- Do not overfill the vacuum pump oil beyond the level/fill line. The pump capacity is
0.7 L (0.74 qt) . The vacuum pump will leak if the pump oil is overfilled. - Remove all of the plugs on the flywheel. Apply grease to the O-rings. A sealed vacuum vessel is crucial in order to avoid problems at start-up mode.
- To minimize the time for vacuum draw, the flywheel should be recharged with nitrogen. Because the flywheel is a casting, there will be some leakage of the charged nitrogen over time. To ensure that the flywheel stays dry and free from water vapor, charge the flywheel with a slight positive pressure of dry nitrogen. The procedure will ensure that the UPS is able to achieve vacuum levels at start-up mode.
- Remove the air bubbles from the vacuum system. To remove bubbles, turn the switch for the ballast from the 0 position to the II position. The switch for the ballast is located on the top middle of the pump behind the exhaust port. Run the pump for 1 hour. Return the switch for the ballast to the 0 position and allow the pump to pull a vacuum.
If a vacuum of less than 35 millitorr cannot be drawn in 3 hours or less, use the procedures in the following sections:
- "Reading of a Vacuum Above 200 Millitorr"
- "Reading of a Vacuum 35 to 200 Millitorr"
Reading of a Vacuum Above 200 Millitorr
Visually check and torque all fittings, ports, and connections in order to address any obvious faulty workmanship. If no faults are found, the pump must be dead-headed with a gauge. Check the pump in order to determine if the pump can pull ten millitorr vacuum.
Reading of a Vacuum 35 to 200 Millitorr
The vacuum pump must be operating. With the vacuum pump in operation, spray methanol on the potential vacuum leaks. Carefully eliminate the following possible source of problems:
- Pins (armature)
- "Comm/Accel" sensor
- Ports on top of flywheel
- Ports on bottom of flywheel
- Sensor port for the vacuum
- Bearing cartridges
- Temperature sensors
- 9-pin temperature sensor
- Vacuum hoses
- Elbows
Observe the pressure reading for the vacuum with UPSView. If the vacuum rises from 10 millitorr to 30 millitorr, then that location is one source of the vacuum leak. A repair must be made to any sources of vacuum leaks. If no leaks are found, then the vacuum pump needs to be dead headed with a gauge. Check the vacuum pump in order to determine if the vacuum pump can pull a vacuum of ten millitorr.
Dead Head Testing of the Vacuum Pump
- Verify that the system is in bypass mode. Verify that the flywheel is disengaged.
- De-energize the vacuum pump.
- Disconnect the input vacuum hose and the 90 degree elbow assembly between the flywheel and the right side of the vacuum pump.
- Connect the 295-5409 Adapter Plate into the fitting for the vacuum pump. See Step 3.
- Connect the 200-8452 Vacuum Sensor to the 295-5409 Adapter Plate.
- Wire the ethernet cable from the sending unit to the "J10" connector on the flywheel interface board. The existing ethernet cable that is attached to the board will need to be temporarily removed.
- Energize the pump. Observe if vacuum is being pulled to less than ten millitorr on UPS HMI or UPSView.
- If vacuum is pulled, then the pump is good. The vacuum system that is external to the pump has a leak.
If troubleshooting procedures uncover no problem, then the flywheel may be faulty. Contact Caterpillar technical support .