Inspection and Cleaning Procedure For Certain Uninterruptible Power Supplies{4480} Caterpillar

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)

UPSB 125 (S/N: SEP1-UP)

UPSB 130 (S/N: XTC1-UP)

UPSB220 (S/N: JFA1-UP)

UPSB505 (S/N: YTM1-UP)

Introduction

This Special Instruction provides inspection and cleaning procedure for certain Uninterruptible Power Supplies.

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.

ReferenceRefer to the Safety section in the Operation and Maintenance Manual, SEBU8515, "UPSB130 Uninterruptible Power Supply UPS Battery - 60 Hz " before proceeding with any work on the UPS.

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. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Failure to connect the unit to a suitable grounding electrode creates an electrical shock hazard. An electrical shock will result in serious personal injury or death.

High voltage levels are present within the UPS. The UPS should be opened only by service personnel that are qualified. The UPS must have a proper ground connection to earth.

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High voltage may be present. Work on this equipment must be performed by authorized trained personnel. Failure to disconnect the power source before performing maintenance or removing modules exposes personnel to electrical potential. Bodily contact with electrical potential will cause serious personal injury or death.

After power is removed, wait for 5 minutes before the UPS is opened. This action allows the capacitors to discharge. Ensure that the capacitors are at a zero energy level before performing work.

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High voltage is present. Work on this equipment must be performed by authorized trained personnel. Personnel must be wearing Personal Protective Equipment that meets regulatory requirements to protect the body for the work that is being performed. Failure to use appropriate PPE to protect the body will result in serious personal injury or death.

Ensure that the UPS is powered down and de-energized.

Ensure that all lockout/tagout procedures for the site are followed to ensure that power is not applied while the equipment is being serviced.

Dust Diagnosis

Tools Required

• Magnet

Inspection of Dust Sample

Perform the following steps to collect and inspect the dust sample.

1. Collect a dust sample from around the UPS.

2. Collect a dust sample from inside the UPS.

3. Analyze each sample with the magnet method.
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   Illustration 1	g03329243

   1. For each sample taken, gather the dust in a sheet of paper.
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   Illustration 2	g03329242

   2. Move the magnet on the backside of the paper, to attract any metal particles contained within the dust.

   3. If the dust moving when the magnet is moved, the dust is magnetic and therefore conductive.

   4. Analysis results and required action are listed in Table 1.
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      Table 1

      Magnet Test	Cleanliness Conditions	Required Action
      Positive (some particles move)	Any conditions	Perform a deep dust cleaning
      Negative (no particles move)	Any doubts exist: Level of dust is of concern. Other conductive material may be present, but not detected ( such as Copper, Aluminum)	Perform a deep dust cleaning
      Negative (no particles move)	No doubt exists: Room and unit are obviously clean	Cleaning procedure not required

Deep Dust Cleaning of UPS

Tools Required

Cleaning Procedure

Perform the following procedure to clean the UPS.

1. Room and Environment.

   1. Bypass and shutdown all UPS in the installation.

      Note: All standard safety rules must be followed.

   2. Start vacuuming from the farthest point away from the UPS and work towards the UPS until the entire area and all horizontal surfaces have been cleaned.

   3. If false floor exists, be sure to clean under the floor.

   4. Vacuum under and between the UPS.

2. Inside the UPS (clean one UPS at a time keeping other units closed).

   1. Remove front protection panels.

   2. Remove back panel of the UPS.

   3. Vacuum inside of the UPS completely.
      • It is important to use a vacuum with a soft bristled brush to remove as much dust as possible before using a blower.

      • Vacuum all spaces where dust can accumulate (such as horizontal surfaces, corners).

   4. With an ESD brush, clean boards and components where dust is visible.

   5. Starting at the front of the UPS, use the blower to blow remaining dust particles from the UPS.
      • Blow from the top of the UPS down to the bottom of the UPS.

      • Blow all spaces where dust can accumulate (such as horizontal surfaces, corners).

   6. Vacuum behind, under and around the UPS to remove any dust blown loose.

   7. After cleaning:
      • Make sure that no dust and particles remain in the unit.

      • Check all parts inside the unit (such as boards, connectors, bars).

   8. Replace all panels and close the doors.

   9. Reinstall all cables removed.

   10. Repeat step 2.a through step 2.i for remaining units.

   11. Restart all units in Manual Mode.