Vacuum Pumps & Conveying System Components Part Number: A0571050 Bulletin Number: SM2-605A.4 Effective: 8/5/04 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No.
Please note that our address and phone information has changed. Please reference this page for updated contact information. These manuals are obsolete and are provided only for their technical information, data and capacities. Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied upon.
Shipping Info Unpacking and Inspection You should inspect the mechanical components of your conveying system for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
Returned Material Policy Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department. Credit Returns Prior to the return of any material authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned. Reason for requesting the return must be given. ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00 minimum) restocking charge. ALL returns are to be shipped prepaid.
Table of Contents CHAPTER 1: SAFETY.................................................................... 6 1-1 1-2 1-3 How to Use This Manual ............................................................................................ 6 Safety Symbols Used in this Manual.....................................................................6 Warnings and Precautions ......................................................................................... 7 Responsibility.......................................
4-3 High Vacuum Relief Regulator Operation ...........................................................36 Shut-down ............................................................................................................... 36 CHAPTER 5: MAINTENANCE.................................................... 37 5-1 5-2 Preventative Maintenance Schedule......................................................................... 37 Preventative Maintenance...........................................................
Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining the mechanical components of your conveying system. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer.
Conveying System Safety Tags Spraying Read Operation Hazard and Installation Manual High Voltage Earth Ground Inside Enclosure PE Lifting Point 1-2 Protected Earth Ground Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international regulations.
˛ When welding or brazing in or around this equipment, make sure VENTILATION is ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with sheet metal. An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed. ˛ Do not restore power until you remove all tools, test equipment, etc., and the equipment and related components are fully reassembled. ˛ Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment.
Operator Responsibility The operator’s responsibility does not end with efficient production. The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations. Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or through a casual attitude toward machinery formed over a period of months or years. Your employer probably has established a set of safety rules in your workplace.
• Clean the conveying system and surrounding area DAILY, and inspect the machine for loose, missing or broken parts. • Shut off power to the conveying system when it is not in use. Turn the switch to the OFF position, or unplug it from the power source. Maintenance Responsibility Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety a priority to effectively repair and maintain equipment.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and maintenance instructions for the mechanical components of the conveying system. Model numbers are listed on the serial tag. Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service.
Basic System Types Time-Fill Systems A time-fill system conveys material to an on-line vacuum receiver for a pre-set time period. When this interval elapses, the controller conveys material to the next on-line vacuum receiver. Volume-Fill Systems A volume-fill system conveys material to an on-line vacuum receiver until the material level activates the proximity switch in the vacuum receiver, or a preset time elapses.
Figure 1: Positive Displacement Pump Dimensions Unit size hp 5 10 15 Unit size kW 3.75 7.5 11.25 A B C Dimensions (inches) D E F G 33 27.5 85.82 29 22 21.75 31.
3.5, 6.5 & 11 Hp Centrifugal Pumps • Centrifugal blower. • Cartridge filter. • Vent valve • Junction box with starter mounted on unit. Figure 2: Centrifugal Pump Dimensions Unit size hp 3.5 5 11.0 Unit size kW 2.63 4.84 8.20 A 15 A 38 B 26.25 24.5 31.5 B 67 62 80 C 17.4 C 44 Pumps & Conveying System Components D 13 13 14.8 Dimensions (inches) E F 8.75 12 7.5 8.6 D 33 33 37 Dimensions (cm) E F 22 30 19 21 Chapter 2: Functional Description G 17.75 G 45 H 35 31 35.5 I 18 17.
Figure 3: Pump Specifications Model Amp draw, full-load amps hp 230 V 460 V 575 V Pumps — Positive Displacement Models 5 13.4 6.7 5.4 10 28.4 14.2 11.4 15 38.4 19.2 15.3 Pumps — Centrifugal Models 3.5 9.1 4.6 3.0 6.5 12.9 6.5 4.3 11 32.5 16.2 10.6 Air flow Å cfm 120 200 300 106 152 225 Line size inches Vacuum Material 2.0” 2.5” 3.0” 2.0” 2.5” 3.0” Vacuum Material 2.0” 2.0” 2.5” 1.5” 2.0” 2.
Atmospheric Valves Models AV1.5, AV2, AV2.25, AV2.5, AV3 • Mount on cover of vacuum hopper to direct vacuum into hoppers. • Relieves vacuum by allowing an in-rush of atmospheric air into the system. • Compressed air-operated. • Selection of black or white neoprene plungers or available high temperature plungers. • 24 VDC control voltage solenoid. • Adds only inches to the height of vacuum hoppers and filter chambers.
Sequence T-Valves Models SV1.5, SV2, SV2.25, SV2.5, SV3, SV4, SV4.5, SV5 • Mount in vacuum header piping above vacuum hoppers to direct vacuum into hoppers. • Compressed air operation. • Selection of black or white neoprene plungers, or high temperature silicone plungers. • 24 VDC control voltage solenoid.
Filter Chambers Specific Features on FCK Models • 24 VDC • Filter surface of 3.2 sq. ft. (0.3 m2). • Compressed air filter cleaning. • 2” connections • Weight Approx. 31 lbs. (14 kg) Specific Features on FCA Models • 24 VDC • Filter surface of 17.2 sq. ft. (1.6 m2). • Implosion filter cleaning. • 2.5” connections • Weight Approx. 117 lbs. (53 kg) Specific Features on FCS Models • 24 VDC or 110 V • Filter surface of 50 sq. ft. (4.6 m2). • Compressed air and implosion filter cleaning. • 2”, 2.
FCA FCK FCS Floor Stand 26 (66) Floor Stand 26 (66) 26 (66) A inches 16.5 A Inches 13.3 13 Note: B inches cm 54.5 138 cm 42 cm 34 33 B inches 45 34.5 C inches 34.3 cm 114 88 C inches 32.3 32 D cm 87 inches 14.25 E cm 36 inches 26 cm 66 cm 28 26 E inches 26 26 cm 66 66 D cm 82 81 inches 11 10.25 Dimensions are approximate and subject to change without notice. Pickup Tubes Take-Off Compartment Models: Single and dual tube take-off compartments are available.
2-4 Safety Devices and Interlocks This section includes information on safety devices and procedures that are inherent to the mechanical components of the conveying system. This manual is not intended to supersede or alter safety standards established by the user of this equipment. Instead, the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment.
In addition to the safety devices listed above, these mechanical components are equipped with a line cord plug. This allows the operator or maintenance personnel to unplug the system from its power source and tag it out. The plug can then be tagged with any number of approved electrical lockout tags available at most electrical supply stores. WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air) sources prior to servicing or cleaning the conveying system.
Chapter 3: Installation 3-1 Uncrating the Equipment The mechanical components of the conveying system are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 1. Pry the crating away from the skid. Note: Remove the nails holding the box to the skid and lift the box off carefully; avoiding staples in the 1’ x 4’ wood supports. Cut the steel banding. 2. Use a pry bar to remove the blocks securing the unit to the skid. 3.
• Use piping or ducting at least two (2) diameter sizes larger than the vacuum connection. Overall vent pipe length—horizontal plus vertical—should not exceed 100 feet (about 30 m) and should not include more than three (3) elbows. If you use pipe for venting, make sure that you use Sch. 5 or Sch. 10 pipe with long radius elbows to provide minimum airflow resistance.
• Cut tube ends square and chamfer edges smooth. Use a fixed band saw or power miter saw when making cuts. You can use a tubing cutter on aluminum tubing, but you need to use a saw with a carbide or diamond-impregnated saw blade when cutting stainless steel. Chamfer outer and inner edge cuts with a die grinder or a hardened rasp file. • Clean all tubing after cutting and before assembly.
• Multiple line systems have separate material lines for each material to allow different types of materials to be conveyed. • Multiple line systems have separate pickup devices for each vacuum hopper. • Materials are often loaded from beside the processing machine from gaylords, grinder takeoffs, and storage bin takeoffs.
• Single line Y piping systems use a common material line for all vacuum receivers connected to a pump and are typically used to convey material from a central supply to several stations. • If you are installing a single line Y system, use Y tubes on the material lines. A Y tube is installed with the branch arm leading to the next station on top and the straight portion that supplies material to the station underneath. • Connect a short-radius bend to the straight portion as close to the Y as possible.
Figure 10: Manifold Y-Tube Installation Figure 11: Typical Single-Line Y-Tube Installation Pumps & Conveying System Components Chapter 3: Installation 27
Material Check Valves in Single Line Y-Tube Systems Pumps & Conveying System Components Chapter 3: Installation 28
• Check valves are a critical feature on single line Y systems. You must have a check valve installed on the material inlet inside the receiver on all vacuum hoppers in single line Y installations. • Check valves must open when the receiver is being loaded and seal to prevent a vacuum leak when other hoppers are being loaded. • Vacuum receivers for these systems have a special factory-installed extended material inlet tube to hold the check valve.
Installing FCA, FCK, or FCS Filter Chambers The filter chamber protects the vacuum pump from damage caused by material carry-over. Primary system filtration occurs in the filter chamber, not in the vacuum receivers. This reduces maintenance of vacuum receiver filters atop processing machines. At the end of the conveying cycle to all on-line vacuum receivers, the dump delay cycle occurs.
Figure 13: Filter Chamber Installation, Optional Blowback Controller Shown Note: Make sure you have all tubing supported at ten (10) foot (3 meter) intervals.
Installing Vacuum Receivers and Inventory/Vacuum Receivers Vacuum uses one of three mounting systems: flange, suspension, or silo mounting. Vacuum receivers and inventory vacuum receivers use flange mountings only. 3-3 Compressed Air Connections Making Pump Compressed Air Connections Connect the vacuum pump to a minimum of 60 psi to 80 psi (414 kPa to 552 kPa) source of clean, dry, lightly lubricated compressed air. Make the 1/8” NPT (3 mm) connection at the solenoid valve on the pump package.
Plug the controllers’ power cord into a properly grounded, 3-slot, 115/1/60 VAC or 230/1/60 VAC receptacle as specified on the control panel serial tag and the enclosed controller Operation and Instruction manual. The control enclosure draws less than 5 amps during normal operation at 115/1/60 VAC. Caution! The manufacturer recommends that you protect PLC memory by providing the control panel with a dedicated circuit, a true earth ground, and a spike/surge protector.
3-5 Initial Start-up Making Startup Checks Before operating the pumps or any other part of the conveying system, check these details: 1. All components in the system must be installed securely and prepared for operation. Refer to the instructions supplied with auxiliary equipment for specific checks. 2. Couplers, fittings, attachments, and flexible lines must be attached securely and be vacuum-tight. 3.
Chapter 4: Operation 4-1 Start-up 1. Check the pump for any obstructions that may cause damage. 2. Turn on the compressed air supply to the atmospheric valve on the pump junction box. 3. Switch the disconnect on the pump junction box to the ON position. 4. The pump is now on line and ready for operation. 4-2 Operation Procedures When you activate the controller, the system energizes and initiates the conveying cycle. The following components energize: • The vacuum pump motor starter.
High Vacuum Relief Regulator Operation A factory-set pressure regulator is installed on the pump package vent valve as a mechanical back-up safety feature. It protects the pump motor from damage during high vacuum conditions if an undetected failure of the vacuum switch should occur. The regulator is set to limit system vacuum to 15” Hg (475 millibars) by allowing the vent valve plunger to shift and vent the pump. Note: 4-3 Do not adjust the pressure regulator.
Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule The checklist below contains a list of items which should be inspected and/or replaced to keep the mechanical components of your conveying system operating at peak efficiency. Perform each inspection at the regular intervals listed below.
5-2 Preventative Maintenance Maintaining Pump Packages Pump packages need periodic maintenance to provide long dependable service. Check these elements regularly: • Maintain a proper oil level in the blower gearbox. The manufacturer’s brochure (packed with the pump package) recommends oils, and lists instructions for checking the oil level. • Pack blower bearings with high temperature ball bearing grease and change the oil to the manufacturer’s recommendations.
Chapter 6: Troubleshooting 6-1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal trouble-shooting must be accomplished with the power off, line fuses removed, and with the machine tagged as out of service. The use of good quality test equipment cannot be over-emphasized when troubleshooting is indicated.
Problem Possible Cause The field-installed station bypass switch is bad or miswired. Insufficient compressed air to shift valves. A vacuum receiver bypasses in the Loading cycle. Cont’d. (Refer to enclosed Control Panel Manual) The Bin-Full switch sensor fails to close. The Receiver-Full proximity sensor is fouled, creating a false reading (Volume Fill systems only). The Receiver-Full proximity sensor has failed closed (Volume Fill systems only). Pressure is present at the vacuum inlet.
Problem High-Vacuum alarm. Cont’d. Possible Cause Faulty vacuum switch. Possible Remedy Test – ON – replace switch. Take off compartment closed. Adjust take-off box. Conveying times are too long (Time Fill only). Vacuum receivers are being overfilled. (Refer to enclosed Control Panel Manual) Special convey enabled. Maximum conveying times are too long (Volume Fill only) and the Receiver Full proximity switch(es) are not being recognized by the PLC. Poor take-off adjustment.
Problem Optional audible/visual alarm installed on a Volume Fill system continues to signal after the Press-To-Silence button is pressed. Possible Cause The operator may: The alarm is triggered every time an alarm message displays. (Refer to enclosed Control Panel Manual for specific instructions.) Optional audible alarm is not functioning. Possible Remedy In cases where numerous alarm conditions occur, alarm messages build up in the display buffer.
Problem Vacuum conveying rate is declining due to a vacuum loss in the system. Possible Cause Pump package blower problem. Use a cfm/cfh monitoring device to ensure that blower cfm/cfh is to the manufacturer’s specifications. Consult Sevice Engineer if problem persists. Pumps & Conveying System Components Chapter 6: Troubleshooting Possible Remedy • Blower is dead-headed. Check for obstruction. • Vent valve is not operating.
Problem Possible Cause Pump package blower problem. Use a cfm/cfh monitoring device to ensure that blower cfm/cfh is to the manufacturer’s specifications. Consult Service Engineer if problem persists. (Cont’d.) Leaks in vacuum lines between valves. Vacuum conveying rate is declining due to a vacuum loss in the system. (Cont’d.) Vacuum leak(s) in vacuum hoppers. Vacuum leaks in material lines. Pumps & Conveying System Components Chapter 6: Troubleshooting Possible Remedy Vacuum line problem.
Problem Possible Cause Vacuum conveying rate is declining due to a vacuum loss in the system. Material take-offs not properly adjusted. (Cont’d.) The blower is dead-headed. Material is sucked from the filter chamber and through the blower. Filters in the filter chamber are dislodged, worn, or not seated properly on the gasket. The material conveyed is not what the system was designed for. Very dusty materials have different conveying needs.
Chapter 7: Appendix 7-1 Warranty The manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. The company’s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser, and which, in the company’s opinion, are defective. Any replacement part assumes the unused portion of this warranty.
7-2 Technical Specifications Annex B Information The following design information is provided for your reference: 1. No modifications are allowed to this equipment that could alter the CE compliance 2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit) 3. Humidity range: 50% relative humidity 4. Altitude: Sea level 5. Environment: Clean, dust-free and non-explosive 6. Radiation: None 7. Vibration: Minimal, i.e. machine mounting 8.
27. Color-coded (harmonized) power cord is sufficient for proper installation. 7-3 Spare Parts List Figure 14: Positive Displacement Vacuum Pump Spare Parts List HORSEPOWER QTY 5 5 5 5 5 5 5 5 5 5 5 5 1 1 1 1 1 1 1 1 1 1 1 1 A0571182 A0538259 A0538247 W00000145 W00013524 W00017811 A0571127 A0571128 W00052176 W00532583 A0547948 W00052800 PART NO BLO,ROOTS,33RAI-J,WHISPAIR,DSL SHV,2-3V4.5,P1,BSHG,BLOWER SHV,2-3V,6.9,Q1,BSHG,MOTOR ORNG,BUNA70,1.984ID X 0.139CS PLGR,2.
Figure 14: Positive Displacement Vacuum Pump Spare Parts List Cont’d. HORSEPOWER QTY 5/10/15 5/10/15 5/10/15 1 1 1 5/10/15 5/10/15 5/10/15 5/10/15 5/10/15 5/10/15 5/10/15 5/10/15 5/10/15 5/10/15 5/10/15 5/10/15 5/10/15 5/10/15 1 1 1 1 1 1 1 1 1 2 2 1 1 3 FT PART NO DESCRIPTION A0069307 A0547079 35085K TBG,PE,0.250OD X 0.040W,NAT GAUG,VAC,2.
Figure 15: Centrifugal Vacuum Pump Spare Parts List HORSEPOWER QTY 3.5/6.5 3.5/6.5 3.5/6.5 1 1 1 W00000145 W00013524 W00017811 PART NO ORNG,BUNA70,1.984ID X 0.139CS PLGR,2.38OD,EPT,BLK,3/8-16,CS GSKT,VELOMOID,2-2.25SEQ VLV 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.5/11 3.5/6.
7-4 Identification (Serial Number) Tag (Located on back of Component of Conveying System) Company Logo XXX Series Vacuum Pump Model Number XXX-5 Max Conveying Capacity HR 460V Serial Number 060701R 1_ Date of Manufacture 06/2003 4.5A Over-current Protection Device (s) 4.
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