Note: The vacuum pump has a tamperproof label. This prohibits the service technician from reconfiguration of the pump and utilization of a 120 VAC source in order to begin the process of vacuum draw on the flywheel during the commissioning procedure. A tamperproof label that is corrupted will void any warranty claim that is associated with the vacuum pump.
- When you change the bearing reloaders in order to install bearings, do not run the vacuum pump. The vacuum pump could circulate contaminants from the outside air into the system.
- When you change the bearing reloaders in order to install bearings, complete the procedure in a timely manner.
- 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. 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. This will ensure that the UPS is able to achieve vacuum levels quickly at start-up mode.
- Remove the air bubbles from the vacuum system by turning 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 a reasonable amount of time (3 hours or less), follow 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 needs dead-headed with a gauge. Check the pump in order to determine if the pump can pull 10 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 needs 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 10 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.
- 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 10 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 .