- Uninterruptible Power Supply:
- ES12F (S/N: CZE1-UP)
- UPS 1000S (S/N: CZS1-UP)
- UPS 1000Z (S/N: EDZ1-UP)
- UPS 120 (S/N: CNK1-UP)
- UPS 1200S (S/N: CZT1-UP)
- UPS 1200Z (S/N: HDR1-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)
- UPS500G (S/N: TYD1-UP)
- UPS600G (S/N: DLD1-UP)
- UPS 1000S (S/N: CZS1-UP)
Introduction
This Special Instruction contains information for testing the vacuum pump on certain Uninterruptible Power Supply. The dead head test can be performed to verify that the vacuum pump is capable of pulling the required vacuum on the system.
Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.
Important Safety Information
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use.
Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
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Power source must be disconnected before working on equipment. Failure to disconnect power source could result in injury or death. |
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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures. |
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Personal injury or death can result from high voltage. Moisture can create paths of electrical conductivity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls "DO NOT OPERATE". |
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Procedure for Performing Dead Head Test On Vacuum Pump
Follow the procedure listed below for performing dead head test on vacuum pump:
- Verify that the UPS is in "Bypass" mode. Verify that the flywheel is "not spinning".
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| Illustration 1 | g03136158 |
295-5408 Sensor Kit (VACUUM PUMP DEAD HEAD) (1) 295-5409 Adapter Plate (2) 200-8452 Vacuum Sensor | |
- De-energize the vacuum pump.
- Disconnect the input vacuum hose (3) and the 90-degree elbow assembly between the flywheel and the right side of the vacuum pump.
Note: The vacuum pump will need to be moved away from the AC capacitors by removing the mounting bolts, to gain clearance for the 295-5408 Sensor Kit .
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| Illustration 2 | g03136237 |
(3) Input vacuum hose | |
- Connect the 295-5409 Adapter Plate (1) into the fitting for the vacuum pump. Use only fingers to tighten the connection clamp.
- Route the standard Ethernet cable from the sending unit to the "J10" connector on the flywheel interface board. Temporarily remove the existing Ethernet cable that is attached to the flywheel interface board.
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| Illustration 3 | g03136238 |
(4) 295-5408 Sensor Kit (VACUUM PUMP DEAD HEAD) | |
- Energize the vacuum pump and allow the vacuum pump to pull for 30 seconds. Observe if vacuum is being pulled to less than 10 mTorr on UPS HMI or UPSView.
- If the vacuum pump pulls between 10 mTorr to 20 mTorr, it could be poor oil condition. Replace the oil in the vacuum pump with fresh oil.
Note: If the oil is contaminated, it may take up to three oil changes to resolve the contamination. Make certain to drain as much oil as possible from the vacuum pump by tipping the vacuum pump at an angle.
- Fill the vacuum pump with fresh oil and run the vacuum pump for 30 minutes.
- Purge the vacuum pump for 10 minutes to 15 minutes.
- Repeat the vacuum dead head test.
- If vacuum pump is considered faulty and the level is still above 10 mTorr, the vacuum pump should be replaced.
- If the vacuum is less than 10 mTorr, the vacuum pump is good.