Storage and Troubleshooting for the Vacuum Pump {4287} Caterpillar

Uninterruptible Power Supply:

UPS 1000S (S/N: CZS1-UP)

UPS 120 (S/N: CNK1-UP)

UPS 1200S (S/N: CZT1-UP)

UPS 150 (S/N: CPC1-UP)

UPS 250 (S/N: BEE1-UP; CNM1-UP; APZ1-UP)

UPS 300 (S/N: CNJ1-UP; CPZ1-UP)

UPS 301 (S/N: CSY1-UP)

UPS 500 (S/N: CSE1-UP)

UPS 600 (S/N: CTX1-UP)

UPS 750 (S/N: CPM1-UP)

UPS 900 (S/N: CRY1-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is provided below.

Problem

The vacuum pump has incurred an early hour failure due to one or more of the following results:

• improper procedure for storage

• improper setup procedure

• improper troubleshooting procedure

Solution

The following procedures will provide enhanced information regarding the vacuum pump:

• procedure for storage

• setup procedure

• troubleshooting procedure

Procedure for Storage

Normal Operating Range

Minimum temperature ... 0 °C (32 °F)

Maximum temperature ... 40 °C (104 °F)

Range of Humidity

Minimum Humidity "Non-condensing" ... 5%

Maximum Humidity "Non-condensing" ... 95%

The vacuum pump has the following specifications for short term storage:

Short Term Temperature Range

Minimum temperature ... −25 °C (−13 °F)

Maximum temperature ... 70 °C (158 °F)

Short Term Range of Humidity

Minimum Humidity "Non-condensing" ... 65%

Maximum Humidity "Non-condensing" ... 95%

Short Term Storage - Short Term defines the storage period of two months or less.

Short Term conditions cover the time when the equipment is in transit from the factory to the dealer or from the dealer to the customer site. The system should be stored under short term conditions for only two months or less.

The vacuum pump has the following specifications for long term storage:

Long Term Temperature Range

Minimum temperature ... 0 °C (32 °F)

Maximum temperature ... 40 °C (104 °F)

Long Term Range of Humidity

Minimum Humidity "Non-condensing" ... 5%

Maximum Humidity "Non-condensing" ... 95%

Long Term Storage - Long Term defines the storage period of three to twelve months.

The system can be stored under long term conditions without any additional concerns. If the UPS is stored longer than one year, you will need to change the oil for the vacuum pump. Thereafter, change the oil in the vacuum pump annually. After completing the oil change for the vacuum pump, you will need to energize the vacuum pump. Operate the vacuum pump for four hours. Operation of the pump will ensure proper lubrication of the seals for the vacuum pump.

The vacuum pump is shipped from Service Parts without oil. Therefore, you are not required to change the oil for the vacuum pump for any inventory from service parts.

Do not utilize a vacuum pump that has exceeded specifications for storage of the vacuum pump. Do not utilize a vacuum pump that has exceeded the operational environmental specifications of the vacuum pump. The vacuum pump must be replaced. The replacement cost of the vacuum pump is not a warrantable repair.

Setup Procedure

The vacuum pump has a tamperproof label. This prohibits the service technician from utilizing a 120 VAC source to begin the process for 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.

To operate the vacuum pump prior to commissioning the system, 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. Ensure that you have removed the external 240 VAC source prior to energizing the input terminals.

Refer to the appropriate Operation and Maintenance Manual when you perform the following procedures:

• commissioning of the UPS

• replacement (field service) of the vacuum pump

• installation of bearings for the flywheel

In addition, perform the following operations:

• When you change the bearing retainers in order to install bearings, complete the procedure in a timely manner. Installation of the bearings in place of the bearing retainers should be completed prior to energizing the vacuum pump. Efficient installation will minimize any possible contamination of the chamber for the flywheel. Efficient installation should decrease the time that is required to create an acceptable vacuum level within the chamber for the flywheel.

• Do not use a 120 VAC source to begin the vacuum draw on the flywheel.

• Remove any externally connected 240 VAC source from the vacuum pump.

• Perform a thorough inspection of the vacuum lines and connection points. Look for any possible discrepancies that could result in a vacuum leak.

• Verify that the vacuum pump has clean, fresh oil. Verify that the oil for the vacuum pump is filled to the appropriate level. Use 190-8487 Vacuum Pump Oil for the vacuum pump. The pump capacity is 0.7 liters. The capacity of the container for the oil (service parts) is 1.0 liter.

• Do not overfill the reservoir for the vacuum pump. Overfilling the reservoir will cause the following results: misting oil from the vacuum pump, contamination of the interior of the UPS and the appearance of a leaking vacuum pump.

• The vacuum pump is equipped with two control switches. One switch controls the gas ballast. The other switch controls the operation mode of the vacuum pump. For normal operation of the vacuum pump, turn the gas ballast switch to the Closed position ("O"). The switch for the mode selector is in the Full Clockwise position.

• 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.

• For systems that have been in dealer storage with an age equal to or exceeding 12 months, lubricate the O-ring seal of the polymer elbow. The O-ring is located on the suction side of the vacuum pump. Utilize 6V-2055 Grease for the O-ring.

Troubleshooting Procedure

A properly sealed flywheel with a properly operating vacuum pump will yield a minimum reading for the vacuum of 35 millitorr within three hours of operation.

If the results of your troubleshooting indicate that the fault actually resides with the vacuum pump, perform a "Dead Head" test on the vacuum pump. To perform the "Dead Head" test, you will require the following service tool:

• 295-5408 Sensor Kit ("Dead Head")

1. Verify that the system is in bypass mode. Verify that the flywheel is disengaged. Refer to the appropriate Systems Operation, Testing and Adjusting.

2. De-energize the vacuum pump.

3. Disconnect the input vacuum hose and the 90 degree elbow assembly between the flywheel and the right side of the vacuum pump.

4. Connect the 295-5409 Adapter Plate into the fitting for the vacuum pump. See Step 3.

5. Connect the 200-8452 Vacuum Sensor to the 295-5409 Adapter Plate .

6. Disconnect the wiring harness for the flywheel installed vacuum sending unit at the flywheel.

7. Connect the wiring harness from Step 6 to the test 200-8452 Vacuum Sensor .

8. For a single module unit, connect your laptop computer to the RS-232 connector that is located on the "I/O" board. For a multiple module unit, connect your laptop computer to the RS-232 connector that is located on the "PCI" board.

9. Start the UPSView program. Establish communications.

10. Select the appropriate telemetry tile in order to view the "Vacuum Gauge".

11. Energize the vacuum pump.

12. Monitor the reading of vacuum pressure via UPSView.

13. An acceptable reading for the vacuum pump is 10 millitorr or less. If the vacuum pump produces a reading greater than 10 millitorr, replace the pump.

14. Upon completion of the "Dead Head" test, return the system back to the original configuration.

15. Return the system to on-line status. Refer to the appropriate Systems Operation, Testing and Adjusting.