Vacuum Pumps & Conveying System Components
Contents
1. Note Make sure you have all tubing supported at ten 10 foot 3 meter intervals Pumps amp Conveying System Components Chapter 3 Installation 33 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 NPT 3 mm connection at the solenoid valve on the pump package Your compressed air supply piping should include A shutoff valve for ON OFF control A pressure regulator with gauge An air filter lubricator 3 4 Electrical Connections Refer to local electrical codes the schematic and connection diagrams supplied with this unit and the serial tag for wiring considerations Run all wiring in conduit if codes require it Label all wiring to make any future troubleshooting easier Make all electrical connections tight Making Pump Power Drop Wiring Connections WARNING Be safety conscious High or low voltage can cause serious or fatal injury Installation must be performed by qualified personnel only Always disconnect power source before attempting installation or repair2. Pump packages are connected to a three phase power supply Bring properly sized power leads in conduit to the contacts in the junction box of each pump package in the system Complete the pump wiring connections by performing the following Install a properly sized fused disconnect switch with lockout on the main lines to each vacuum pump package This is recommended even for pumps with optional fused disconnects Check the serial tag for voltage and amperage requirements On 60 Hz units voltage supplied to the unit must be within plus or minus ten percent 1096 of the serial tag value on 50 Hz units within plus or minus five percent 2596 of the serial tag value Phase imbalance must be less than 2 in accordance with NEMA MG1 14 32 Ground the unit for operator safety and equipment protection Pumps amp Conveying System Components Chapter 3 Installation 34 Making Control Panel Power Drop Wiring Connections 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 Connecting the Control Panel to the Pump Package
3. Problem Possible Cause Possible Remedy Optional audible visual alarm installed on a Volume Fill system continues to signal after the Press To Silence button is pressed Refer to enclosed Control Panel Manual for specific instructions Optional audible alarm is not functioning Refer to enclosed Control Panel Manual for specific instructions The alarm is triggered every time an alarm message displays The alarm package is wired incorrectly Alarm package component failure In cases where numerous alarm conditions occur alarm messages build up in the display buffer Each time one is released from the buffer the alarm sounds The operator may Press the silence button after each message Disable the alarm using the control panel keypad Cancel No Convey alarm s Q Correct the problem causing the alarm Alarm will not trigger again until another high vacuum condition occurs If multiple alarm messages are in the buffer the button may need to be pressed a few times Correct wiring Consult wiring diagram Troubleshoot and repair replace problem O To cancel No Convey alarm s Take the problem receiver s off line with field installed station bypass switches Take the problem receiver s off line with the control panel Remove the material demand by filling the bin below the vacuum receiver Pumps amp Conveying System Components Chapter 6 Troubles
4. Refer to enclosed Control Panel Manual Pressure is present at the vacuum inlet No Convey alarm Part of vacuum control panel Refer to enclosed Control Panel Manual High Vacuum alarm Possible Cause The field installed station bypass switch 1s bad or miswired Insufficient compressed air to shift valves 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 onl Improper pump rotation Possible Remedy Repair replace or rewire Supply 80 psi 552 kPa compressed air to all compressed air operated valves Standard switch is normally open held closed by the magnet Check for the presence of the magnet and for proper switch operation Wipe off the proximity sensor Re adjust if needed Replace Switch any two wires at the incoming power Blowback solenoid failed open Material supply empty Check filter chamber or pump Refill the supply Material supply bridging Agitate material supply Pick up device not in supply Re insert the probe Flapper pruciein open Clear flapper of obstructions position Inspect power Replace level sensor Find and remove obstruction Find and repair leak Check for signal sufficient compressed air proper wiring and operation Find and remove the obstruct
5. Note Consult the specific schematics and Operation amp Instruction manual supplied with your controller for your specific application Wire the pump package motor starter coil M to the terminal provided in the conveying system control panel enclosure Wire the pump package vacuum relief valve solenoid SOL A to the terminal provided in the conveying system control panel enclosure Wire the pump package high vacuum switch VS to the terminal located in the conveying system control panel enclosure Note Make sure that the pump motor starter the vacuum relief valve solenoid and the blowback solenoid if supplied are the same voltage 24 VDC as the conveying system control panel control voltage Consult the control panel serial tag and the pump package serial tag Note Wire size depends on control voltage distance number of vacuum hoppers and the number of wires in each raceway Consult a qualified electrician Pumps amp Conveying System Components Chapter 3 Installation 35 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 Electrical and compressed air conn
6. Get tese Ue n CIR e CERE RN CER ERE a E CIR EUR CUR NN Ve PEE EXER YT EXE GERA 37 4 2 Operation Procedures ssssssssssssssssseseee nene ener rhhn nennen nnnm terr nnn nnne nennen 37 Vacuum Switch VS Operation AA ree Eee epit 37 Pumps amp Conveying System Components iv High Vacuum Relief Regulator Operati0D ooooooiccccnncccccooccnnccncnnnccnononanancnnnnnnnnns 38 4 3 SNE IA aee e recede i e erai aede Fon eda ede edd de 38 CHAPTER 5 MAINTENANCE eeeerreeeee nennen nnn 39 5 1 Preventative Maintenance Schedule sssssssssssssseeeeememm 39 5 2 Preventative Maintenance essssssssssssssssseeseee eee nennen nennen rrr rennen nennen 40 Maintaining Pump Packages cooooccccccccnccnccnncccnncnnonccncononccnconnnncnnonnnncnnnnnancnnconaneos 40 CHAPTER 6 TROUBLESHOOTING 41 0 1 IntroductiOn ota ea Rin A e ie ea tr 41 CHAPTER 7 APPENDIX 22 125 ccos coco ecco occae ono ceo ecc see voces 48 fed Matrtanty iuuat A A Deoa pU TUER 48 7 2 Technical SpecificatiONS ooooocccccnncccnnnnnnnccnnnnnnnnnonnnnnncnnnnnnnnnnnnnnnncnnnnnnnnnnnnnannnnnnns 49 Annex B Information ate ich tide de va dt e Y oua dua rou edv a unus deu Uu eaae 49 TES Spare Parts EIS us oreet cette cec e Te wth A a a a awe 50 74 Identification Serial Number Tag nnen 53 7 b Technical ASSIStanCe occoooncncccnonncnncccnoncnnnnnnnnnncnonnnnn
7. banding 2 Use a pry bar to remove the blocks securing the unit to the skid 3 Lift unit from sides inserting forklift under the base The forks must be equidistant from the centerline of the unit and the unit must be balanced on the forks Lift slowly and only high enough to clear the skid Use a pry bar if necessary to carefully remove the skid from the unit 4 Lower slowly 5 Temporary hardware has been installed to prevent side panels from shifting in transit Remove hardware 6 Retain the crating material for reshipping the components in case hidden shipping damage is found Pumps amp Conveying System Components Chapter 3 Installation 23 3 2 Rigging and Placing Mechanical Components Conveying system installations vary depending on the application in plant distribution or rail car unloading single or multiple material line systems pellets or powders The sections on the following pages are general installation guidelines Installing the Pump Package Place the vacuum pump where you can have easy access to the mechanical components Choose a clean dry place where debris won t be drawn into the vent valve on top of the blower If you install the unit outside you must provide a weather shed to shelter the unit 1 Level the vacuum pump package Use shims as needed 2 Secure the vacuum pump package with appropriately sized bolts to the floor or mounting platform 3 Do not twist or warp the pump package base This
8. for conveying pelletized granular or powder material in a central material handling system A typical use is as an in plant distribution system for plastic processing plants Conveying system mechanical components are sized to meet the specific requirements stated by the Customer at the time of purchase 2 2 General Description Our central vacuum systems are as varied as the applications that they service Tubing and equipment furnished in a specially designed system is intended to convey the material s specified at the time of purchase at specific rates and distances We can advise you on your system capabilities based on system makeup distance material and desired conveying rates Pressure drops in the overall system directly affect system capacity such as number of material line bends footage of pipe Y tubes T tubes etc The less distance flexible hose and bends you use on material lines the better Keep material lines as straight as possible Note Vacuum leaks occurring anywhere in your system reduce capacity Basic System Components A typical conveying system contains the following components Vacuum receiver s Vacuum pump Filter chamber e Sequence or atmospheric valves Controller Take off compartments Pickup tubes wands Vacuum and material tubing Combinations of these components will help you build your system for the application you need Pumps amp Conveying System Components Chapter
9. should reach 14 Hg 475 millibars the high vacuum switch closes The pump package tries to clear the line for three seconds then moves to the next on line vacuum receiver The normal conveying cycle continues If high vacuum keeps occurring the pump continues with attempts to clear the line Refer to your specific controller manual for additional operation information Pumps amp Conveying System Components Chapter 4 Operation 37 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 Do not adjust the pressure regulator Adjusting the pressure regulator voids your warranty 4 3 Shut down To deactivate the conveying system 1 Turn the disconnect switch at each pump or component to OFF This will take each pump or component offline 2 Turn off the compressed air supply to the system Note Consult your specific controller operation and instruction manual for specific shut down information for your conveying system Pumps amp Conveying System Components Chapter 4 Operation 38 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule The checklist
10. the tube stub to permit a proper seal Also if the hopper is over filled the check valve may not seal properly Vacuum leak s in vacuum hoppers Vacuum leaks in material Check for leaks as described in lines previous steps Pumps amp Conveying System Components Chapter 6 Troubleshooting 46 Problem Possible Cause Possible Remedy Too much air and not enough material or too much material and not enough air Close takeoff compartment material inlet slowly open until you Material take offs not hear material surging and properly adjusted slugging Close material inlet until surging disappears On most systems a proper Vacuum conveying rate 1s declining due to a vacuum loss in the system Contd adjustment generates a 6 to 10 Hg 203 to 339 millibars vacuum The blower is dead headed Check the blower inlet for obstruction Replace or repair immediately Filters in the filter chamber E p y If the exhaust silencer has oo deso wot Or not material in it replace it to Material is sucked from the seated properly on the gasket event fire s filter chamber and through the PESE TENERENT P gt blower E Mon m adr Consult manufacturer for what the system was designed for Very dusty materials have different conveying needs advice on hardware requirements Other service problems or questions can be answered by contacting the Service Department Pumps amp Conveying
11. 2 Functional Description 12 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 recelver 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 When either of these conditions occur the controller conveys material to the next on line vacuum receiver Equipment Cycle Our bulk material conveying systems are used for automatic pneumatic handling of most free flowing dry pelletized powder granular materials Material characteristics determine the type of equipment needed to properly convey the material See Figures 7 and 11 on Pages 25 and 28 for typical system configurations 2 3 Standard Features 8 Options Pumps 5 10 amp 15 Hp Positive Displacement Support base Positive displacement blower e 3 phase high efficiency TEFC electric motor 5 10 or 15 horsepower 3 75 7 5 11 25 kW Standard voltage is 230 460 3 60 380 415 3 50 220 3 50 and 575 3 60 optional Adjustable motor base Compressed air operated mechanical high vacuum relief valve Vacuum gauge Vacuum switch for high vacuum protection Junction box with motor starter including overload protection Discharge silencer Options
12. O4NWNAT 571015 1 A054709 GAUGYAC2sDO3oSSGEUK sigs 1 3508sK__ STRAIGHT MALE E NPTA OD 5 10 15 1 s35086K ELBOW 1 8 NPT MALE X 1 4 OD sos 1 A0543268 FTG BRBU O2SNPTXI SNPT snons 1 aseo FrGmrEozsNPT saons 1 A053223 NIPBRO2SNPTXOSSLGCL snons 1 W0001396T REGAIRMINT IZ7EFO amp HPRILDR snis 1 WO0I7532 CYLKILSEALAIRIS THP sois 1 weooress CYLAIRS1311 1 5 1SHP 2HOLE snons 1 051252 SOLV3WAY24VDCI NPT snons 1 aous42 NIMCSOISNPTX300UG siis 2 wo0090871 OILMTRAOWFORVACUNITBLWRS snons 2 wewriso BELrv3vxaso O o 57015 1 Aosea2i CONMBOXLTNYLSTROSO snons 1 0562419 CONNBOXLTAYLELS0030 Sins 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 F Pumps amp Conveying System Components Chapter 7 Appendix 51 Figure 15 Centrifugal Vacuum Pump Spare Parts List HORSEPOWER 3 5 6 5 ORNG BUNA70 1 984ID X 0 139CS 3 5 6 5 PLGR 2 380D EPT BLK 3 8 16 CS 3 5 6 5 GSKT VELOMOID 2 2 25SEQ VLV 3 5 6 5 11 TBG PE 0 2500D X 0 040W NAT 3 5 6 5 11 GAUG VAC 2 5D 0 30 SS GF 1 4 3 5 6 5 11 ELBOW 1 8 NPT MALE X 1 4 OD 3 5 6 5 11 REG AIR MINT 1 27E 08 HPR LDR 3 5 6 5 11 CYL KIT SEAL AIR 1 5 7HP 3 5 6 5 11 CYL AIR S1311 1 5 15HP 2 HOLE 3 5 6 5 11 FTG BR BU 0 25NPT X 1 8 NPT 3 5 6 5 11 1 A0543269 FTG BR TE 0 25NPT 3 5 6 5 11 NIP BR 0 25NPT X 0 88LG CL 3 5 6 5 11 STRAIGHT MALE 1 8 NPT
13. S coooccccccnnnccncconncccnconnncnnconnncnnnnnnnncnncnnnncnnconnncnnccnnnacinnnnnnees 8 1 3 Responsibility iet nee Ee e eee eem tete 9 General Responsibility eese senes 9 Operator Responsibility sarnane e ae a irt 10 Maintenance Responsibility eese essen 11 Reporting a Safety Defect eene nna 11 CHAPTER 2 FUNCTIONAL DESCRIPTION 12 2 1 Models Covered in This Manual ccoooonooncncccnnncccnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 12 2 2 General DescriptiOD oooooonnnnnccccncccononnncnnnnnnnnnonnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnninnnnnns 12 Basic System COMpONEN S asias a e a e aa e e aaa aaa Aae aS 12 Basic System Typ6s sisi e tio de ia 13 Equipment Cycle ossi cai AA E VW v EVE elie ee ie ae 13 2 3 Standard Features amp Options sssssssssssssssssseseseeeeeenenennen nennen nnne 13 Pumps ciae ap o EORR ERES OR EYE GERBER A eee 13 Atmospheric Valves sssssssssssssssissssss hien ennt nar hn nsn na hin sene rines nnns 17 Sequence T Valves ssi bd ied dea et da laeta e d dae en 18 Filte Chambers ss s s eie tasa o a ie oia Decio eai e IR Podio Ede radon 19 tx EFE 20 2 4 Safety Devices and InterloCkS oooooonononnncccnnccccnnoncnccnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnncnncnnnnnnns 21 CHAPTER 3 INSTALLATION e eneeeeee nennen nnn 23 3 1 Uncrating the Equipme
14. Some of the safety devices utilize a manual activator This is the method of initiating the safety lock out This may be in the form of a plug lever or a handle Within this lockable handle there may be a location for a padlock Personnel servicing the equipment should place a padlock in the lockout handle Pumps amp Conveying System Components Chapter 2 Functional Description 21 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 Failure to do so may result in serious injury No one but the person who installed the lockout may remove it Pumps amp Conveying System Components Chapter 2 Functional Description 22 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
15. Sound enclosure Premium efficiency motors Pumps amp Conveying System Components Chapter 2 Functional Description 13 Figure 1 Positive Displacement Pump Dimensions Unit size Dimensions inches hp a B C D E F G 33 27 5 85 82 29 22 21 75 31 75 ELS size Se E a ETE mmm i Pumps amp Conveying System Components Chapter 2 Functional Description 14 3 5 6 5 amp 11 Hp Centrifugal Pumps Centrifugal blower Cartridge filter Vent valve Junction box with starter mounted on unit Figure 2 Centrifugal Pump Dimensions Dimensions inches NETA D px Ru SE ig e EA a 25 245 174 12 17 75 86 pimension em LXW 4 S o c r pc p E ts HM a ger 820 Pumps amp Conveying System Components Chapter 2 Functional Description 15 Figure 3 Pump Specifications Amp draw full load amps Ship weight hp zov 40y 575V cfm inches lbs Pumps Positive Displacement Models Vacuum Material 5 10 15 Pumps Conan figal Models Vacuum Material Amp draw full load amps 575 V Pumps Positive Dis
16. System Components Chapter 6 Troubleshooting 47 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 This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the company s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned The company is not liable for any incidental consequential or special damages or expenses The company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts Any sales use excise or other tax incident to the replacement of parts under this warranty is the responsibility of th
17. Vacuum Pumps amp Conveying System Components Part Number 882 000 31 00 Bulletin Number WH2 605B 5 Effective 12 12 12 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 O Copyright 2012 All rights reserved 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 AXCAUTION 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 Please contact the ACS Group for more current information about these manuals and their warnings and precautions Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicat
18. X 1 4 0D 3 5 6 5 11 1 A0571252 SOLV 3WAY 24VDC I 8NPT 3 5 6 5 11 CLAMP HOSE FOR PAN 3816 2 5 3 5 6 5 11 NIP CS 0 13NPT X 3 00LG 3 5 6 5 11 GAUG VAC 2 5D 0 30 SS GF 1 4 3 5 6 5 11 CONN BOX LT NYL STR 0 500 3 5 6 5 11 A0562419 CONN BOX LT NYL EL 90 0 500 3 5 6 5 11 A0562430 CND FLEX NYL 0 500 3 5 BLO 3 5 HP SPC PUMP 208 460 V 3 5 BLO 3 5 HP SPC PUMP 575 V 6 5 BLO 5 HP SPC PUMP 208 460 V 6 5 BLO 5 HP SPC PUMP 575 V 11 BLO 11 5 HP SPC PUMP 208 460 V 11 BLO 11 5 HP SPC PUMP 575 V 11 ORNG BUNA70 2 484ID X 0 139CS 11 PLGR 2 860D EPT BLK 3 8 16 CS n Pumps amp Conveying System Components Chapter 7 Appendix 52 7 4 Identification Serial Number Tag Located on back of Component of Conveying System Company Logo C 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 5A Total Frequency 50 60Hz Compressed air supply 120 PSI Electrical Diagrams amp Street Address City State Zip Code Telephone Number Pumps amp Conveying System Components Chapter 7 Appendix 53 7 5 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 630 595 1060 Fax 630 475 7005 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance
19. and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you Make sure the equipment and components are properly GROUNDED before you switch on power Use extreme caution when working with your conveying system HIGH VACUUM can be dangerous Keep body parts tools clothing and debris away from vacuum inlets 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 We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality Pumps amp Conveying System Components Chapter 1 Safety 8 1 3 Respons
20. and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 233 4819 or call 630 595 1060 Emergencies after 5pm CST call B47 439 5655 We have a qualified service department ready to help Service contracts are available for most products Sales Department Call 630 595 1060 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 630 595 1060 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning System packages including drawings equipment labor and construction materials and union or non union installations Pumps amp Conveying System Components Chapter 7 Appendix 54 Pumps amp Conveying System Components Chapter 7 Appendix 55
21. are located For more information please visit us at www acscorporate com United States Asia Australia India ACS India ACS Schaumburg Corporate Offices ACS Suzhou Gat No 191 1 Sandbhor Complex 1100 E Woodfield Road 109 Xingpu Road SIP Mhalunge Chakan Tal Khed Suite 588 Suzhou China 215126 Dist Pune 410501 India Schaumburg IL 60173 Phone 86 8717 1919 Phone 91 21 35329112 Phone 1847 273 7700 Fax 86 512 8717 1916 Fax 91 20 40147576 Fax 1 847 273 7804 i Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin WI 53151 Ul Dzialkowa 115 Phone 1 262 641 8600 Qe e Rud E Phone 48 22 390 9720 Fax 48 22 390 9724 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 Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a
22. ary refer to the parts catalog section Note Refer to specific control panel operation and instruction manual for additional details and Troubleshooting information Problem Possible Cause Possible Remedy The motor overload tripped Reset the overload and check the motor for the proper amp draw as listed on the serial tag The pump doesn t run even houch son me No demand signal stations offline Refer to enclosed Control Control panel problem Panel Manual Main fuse in power drop or optional fused disconnect has blown The bin below the vacuum receiver is full if the amber receiver indicator light is off A vacuum receiver bypasses in z yP The receiver is off line the Loading cycle Static convey time was set to Refer to enclosed Control Eee Panel Manual Field installed station by pass switch is simulating a bin full condition Check control panel Verify wire connections Inspect output cards Replace the fuse Check for 3 phase voltage Repair or replace as required Normal operation When hopper level drops material begins conveying to it Put it on line via menus Put in a reasonable convey time via menus Normal operation Throw field installed switch to put hopper back in the loading sequence Pumps amp Conveying System Components Chapter 6 Troubleshooting 41 Problem A vacuum receiver bypasses in the Loading cycle Cont d
23. 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 Vidi iit MOD NNNM Date Date Date Date Date Date Date Date Date Date Date Date Date Every week Inspect all filters for EXPE EI I wear replace clean if dirty or o OT Se Te ae an Check to make Ph a SN sure that all hose conections are air tight m Every month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Lock out electrical power and inspect electrical wiring for integrity Check demand sensor Inspect gaskets at hoppers Inspect belt s Oil amp grease lubricate components Photocopy this page for your maintenance records Pumps amp Conveying System Components Chapter 5 Maintenance 39 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 V belts are sized for maximum life with the pump package blowe
24. can misalign the blower housing and damage the blower Vacuum Pump Vent Piping Considerations Most vacuum pumps are installed with no exhaust venting of the vacuum pump discharge If your installation requires vacuum pump exhaust venting follow these guidelines Venting exhaust air from vacuum pumps requires the installation of metal pipe or ducting Make sure that no more than two inches water column 2 WC or about 0 5 kPa back pressure is present at the discharge of the vacuum pump silencer Note Improper sizing or ducting of exhaust air voids your warranty 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 If you use ducting make sure you use high pressure ducting with mitered bends with a minimum of three 3 breaks for minimum airflow resistance Make sure all piping connections are properly supported e f you are venting pump discharge outdoors make sure you properly terminate vent piping to prevent pump damage You can either a Install a rain cap or b Install the piping so the exhaust faces down and terminates with a screened opening Note Ifthe pump becomes contaminated from rain or airborne
25. claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have MI Mechanical Components of Conveying System Bill of lading Packing list Operating and Installation packet KK KR Electrical schematic and panel layout drawings M Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For shipments in the United States and Canada call 1 800 423 3183 for all other countries call our international desk at 414 354 0970 Have the order number and item number available Hold the items until you receive shipping instructions Pumps amp Conveying System Components ii 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 authorizat
26. device Conveying system is not equipped with local lighting Functional identification Conveying system is equipped with a CE mark Conveying system is supplied with an operating manual in the language of the destination country Cable support may be required for power cord depending on final installation No one is required to be in the interior of the electrical enclosure during the normal operation of the unit Only skilled electricians should be inside the enclosure for maintenance Doors can be opened with a screwdriver but no keys are required Two hand control is not required or provided All components should be moved around and set in a place with a lift truck or equivalent There are no frequent repetitive cycles that require manual control repetitive functions are automatic while the conveying system is operating An inspection report detailing the functional test is included with the conveying system The machine is not equipped with cableless controls Color coded harmonized power cord is sufficient for proper installation Pumps amp Conveying System Components Chapter 7 Appendix 49 7 3 Spare Parts List Figure 14 Positive Displacement Vacuum Pump Spare Parts List 5 an o A un ajuajaulujujaulu uj au u S o e A Pumps amp Conveying System Components Chapter 7 Appendix 50 Figure 14 Positive Displacement Vacuum Pump Spare Parts List Cont d HORSEPOWER snons 1 006307 IBGPEG2SOODXO
27. e purchaser The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty Many types of the manufacturer s equipment carry an additional one year service policy Consult your sales representative for specific details Pumps amp Conveying System Components Chapter 7 Appendix 48 7 2 Technical Specifications Annex B Information The following design information is provided for your reference 1 O ON CUN CP G2 c ES 12 13 14 15 16 17 18 19 20 2 22 23 24 25 26 2 No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature 40 degrees Celsius Maximum 104 degrees Fahrenheit Humidity range 50 relative humidity Altitude Sea level Environment Clean dust free and non explosive Radiation None Vibration Minimal i e machine mounting Allowable voltage fluctuation 10 Allowable frequency fluctuation Continuous 1 Intermittent 2 Nominal supply voltage 460 3 60 Verify on serial number tag 11 Earth ground type TN system has one point directly earthed through a protective conductor Power supply should include a ground connection Over current protection is supplied in the conveying system but additional protection should be supplied by the user The door mounted disconnect serves as the electrical disconnect
28. ected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you have completed the repair or maintenance procedure check your work and remove your tools rigging and handling equipment Do not restore power to the conveying system until all persons are clear of the area DO NOT start and run the conveying system until you are sure all parts are functioning correctly BEFORE you turn the conveying system over to the operator for production verify all enclosure panels guards and safety devices are in place and functioning properly Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment Pumps amp Conveying System Components Chapter 1 Safety 11 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 Our mechanical components are designed to create vacuum
29. ections to the pump package vacuum hoppers and filter chambers must be complete safe and conform to code 4 The pump package blower gearbox must be filled with oil as specified in the manufacturer s instructions included in the customer information package Caution Do not overfill the blower gearbox with oil too much oil damages the blower 5 Ifnot done already remove the plastic plug from the silencer air outlet WARNING Keep hands away from the open air inlet to avoid injury 6 Do not allow any loose parts tools or foreign materials in or near the unit and other system components 7 Check for proper motor rotation as indicated by an arrow on the pump package motor Bump start the pump package with the compressed air disconnected just long enough to verify proper rotation direction Note To change motor rotation Disconnect power at the external disconnect Switch any two incoming power leads on the main power supply 8 Make sure that filter chamber housings have no leaks check stretcher clamps for tightness Pumps amp Conveying System Components Chapter 3 Installation 36 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 Operation Procedu
30. ed to providing excellent customer service For immediate assistance please contact e North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com e Mexico Central amp South America Email acslatinamericacustserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com India 91 21 35329112 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you
31. er Grounded flexible hose is recommended f you must cut bends cut the straight section leaving enough straight length for complete insertion into a coupler Youcan attach a quick change or standard tube coupler to vinyl flex hose by inserting a stub of hard tube into the hose and securing it with a hose clamp Be sure enough Pumps amp Conveying System Components Chapter 3 Installation 25 tube extends from the hose to properly install the quick change or coupler Make sure that you put clear silicone caulk around adjoining tube seams for exterior bolted couplers f you use stainless flexible material hose the material flow must be in the direction as indicated by the arrows on the hose Material direction is not critical with vinyl flex hose Bring all truck fill lines to a central location such as a silo unless otherwise specified e All rail car manifold Y tubes must be installed with a ten degree 10 downward slant from horizontal on the leg section Make sure that space between rail car manifold Y tubes are fifteen feet 15 4 5 meters on center to allow proper alignment between rail car discharge ports and the manifold Y tubes A plug must be put in the last sequence T valve on the vacuum header to prevent vacuum loss If atmospheric valves are used you must terminate the vacuum line at the last atmospheric valve Pumps amp Conveying System Components Chapter 3 Installation 26 Multiple Line System Pipin
32. es or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation Pumps amp Conveying System Components Chapter 1 Safety 9 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 Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person REMEMBER NEVER place your hands or any part of your body in any dangerous location NEVER operate service or adjust the conveying system without appropriate training and first reading and understanding this manual NEVER try to pull material ou
33. 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 Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical and pneumatic power Attach warning tags to the disconnect switch and air shutoff valve When you need to perform maintenance or repair work on a conveying system above floor level use a solid platform or a hydraulic elevator Ifthere is a permanently installed catwalk on your conveying system use it The work platform should have secure footing and a place for tools and parts DO NOT climb on the conveying system machines or work from ladders If you need to repair a large component use appropriate handling equipment Before you use handling equipment portable A frames electric boom trucks fork trucks overhead cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable Carefully test the condition of lifting cables chains ropes slings and hooks before using them to lift a load Be sure that all non current carrying parts are correctly conn
34. g Considerations 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 Figure 7 Typical Multiple Line System Installation Pumps amp Conveying System Components Chapter 3 Installation 27 Single Line Y Tube System Considerations 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 f 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 You must connect a minimum 2 foot 61 cm straight length of tube to this short radius bend on the horizontal before the material tubing drops to the receiving point If possible incline this tube approximately s per foot 1 cm per meter On single line Y systems you must ins
35. hat if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Pumps amp Conveying System Components Chapter 1 Safety 6 Conveying System Safety Tags Spraying Hazard High Voltage Inside Enclosure Lifting Point Pumps amp Conveying System Components Chapter 1 Safety Read Operation and Installation Manual Earth Ground Protected Earth Ground 1 2 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 To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices a RA A KR R NA a Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODES Wear SAFETY GLASSES
36. hes cm K 2660 153 34 45 a 323 2 w 28 26 66 Hes 26668 35 337 345 8971 82 sp 1 7 1025 26 26 115687 Note Dimensions are approximate and subject to change without notice Pickup Tubes Take Off Compartment Models Single and dual tube take off compartments are available Pickup Tube Models Single and dual tube pickup tubes available Pumps amp Conveying System Components Chapter 2 Functional Description 20 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 At the completion of this section the operator and maintenance personnel will be able to do the following e Identify and locate specific safety devices e Understand the proper use of the safety devices provided e Describe the function of the safety device Safety Circuit Standards Safety circuits used in industrial systems protect the operator and maintenance personnel from dangerous energy They also provide a means of locking out or isolating the energy for servicing equipment Various agencies have contributed to the establishment of safety standards that a
37. hooting 44 Problem Possible Cause Possible Remedy Vacuum conveying rate 1s declining due to a vacuum loss in the system Pumps amp Conveying System Components 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 Chapter 6 Troubleshooting Blower is dead headed Check for obstruction Vent valve is not operating Check for proper signal voltage and 80 to 90 psi 552 to 621 kPa compressed air Worn seals in blower Rebuild replace blower Worn bearings in blower Rebuild or replace Loose drive belt s Tighten or replace if worn Follow the vacuum path from the blower through the filter piping valves and material receivers to isolate where the loss occurs Filter chamber problem The vacuum at the filter chamber should be the same as the blower generates If the vacuum at the filter chamber is adequate the problem is down line Dirty filter Clean or replace filter Loose clamps gaskets or couplers Tighten or replace Filter chamber discharge flapper not sealing under vacuum Check for proper operation clean or repair as needed Check for faulty compressed air blowback solenoid Check for voltage signal during cleaning cycle proper solenoid operation incorrect wiring proper compressed air connection and for worn plunge
38. ibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machines should become familiar with their operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No mater who you are safety is Important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production e Loss of a skilled operator temporarily or permanently Breakdown of shop morale Costly damage to equipment Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through this group the safety program can be continually reviewed maintained and improved Keep minut
39. id Figure 5 Typical Sequence T Valve Pumps amp Conveying System Components Chapter 2 Functional Description 18 Filter Chambers Specific Features on K Models e 24 VDC e Filter surface of 3 2 sq ft 0 3 m Compressed air filter cleaning 2 connections Weight Approx 31 lbs 14 kg Specific Features on A Models e 24 VDC Filter surface of 17 2 sq ft 1 6 m e Implosion filter cleaning 2 5 connections Weight Approx 117 Ibs 53 kg Specific Features on S Models 24 VDCor 110 V Filter surface of 50 sq ft 4 6 m Compressed air and implosion filter cleaning e 2 2 5 or 3 connections Common Features on All Models K A S For use with Positive Displacement power units e Twenty six inch 26 66 cm high floor stand for drum discharge Reverse pulse filter element Available in floor mount wall mount or pump mount configurations Spare filter cartridge available Pumps amp Conveying System Components Chapter 2 Functional Description 19 Figure 6 A K or S Series Filter Chamber Specifications and Dimensions ne Floor E A IO GN PE A FEOS O A A Stand inches cm inches cm inches cm inches cm inches cm 26 6 d 165 42 545 138 343 87 1425 36 26 66 Floor A B Cc D E k Stand Inches em inches cm inches cm inches cm inc
40. ion such as a coupling gasket Clean filter Clean filter Check for signal sufficient compressed air proper wiring and operation Check for signal sufficient compressed air proper wiring and operation Locate and correct Convey time set too long Reduce convey time Collapsing hoses Inspect hoses Sequence T valve problem where used Material or vacuum line plugged Filter chamber filter dirt Vacuum hopper filter dirty Bad atmospheric sequence T valve Vent valve on pump package not operating correctly Pumps amp Conveying System Components Chapter 6 Troubleshooting 42 Problem Possible Cause High Vacuum alarm Cont d Vacuum receivers are being overfilled Refer to enclosed Control Panel Manual Vacuum receivers are being underfilled Filter chamber filter cartridge 1s becoming obstructed too frequently by fines and dust Pumps and receivers are on line but the pumps are not conveying material Refer to enclosed Control Panel Manual for specific instructions Pumps amp Conveying System Components Possible Remedy Faulty vacuum switch Test ON replace switch Take off compartment closed Adjust take off box Conveying times are too long Time Fill only 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 Po
41. ion must be given by the manufacturer ARMA 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 The invoice number and date or purchase order number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer ARMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty terms Pumps amp Conveying System Components 111 Table of Contents CHAPTER 1 SAFETY 5 iiixdi or A a 6 1 1 Howto Use This Manual sssssssssssseeeeeseem eene mneennmehhnenne rh nnns nna rn nennen nis 6 Safety Symbols Used in this Manual sss 6 1 2 Warnings and PrecautiOn
42. ir cylinders and plugers for proper operation Verify that all safety components circuits are in full operational condition Pumps amp Conveying System Components Chapter 5 Maintenance 40 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 Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to provide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destroy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necess
43. l tube bends elbows Y tubes and vacuum T tubes to a minimum for maximum system capacity Use long radius tube bends on material lines Keep the total length of material conveying flex hose to a minimum Long flex hose material runs reduce system capacity Vertical material tubing runs should be straight up Inclined runs can reduce capacity Support tubing about every ten feet with straps pipe hangers or brackets Tube joints must be rigid to prevent vacuum or material leaks 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 Dampen a rag in a non volatile cleaning solvent and run it through all tubing and couplers to remove sediment from shipping or cutting Run a quantity of low grade material through new lines to remove any remaining sediment then discard the material immediately Tube ends must butt together inside couplers Tighten tube coupler nuts from the center outward to ensure a tight seal and allow proper contact of the internal grounding strip Each material tubing run must maintain an electrical continuity through the tubing and couplers from pickup point to vacuum hopp
44. nlet tube to hold the check valve The check valve must not be pressed too far onto the inlet stub to prevent proper sealing The hinge of the check valve should be up to prevent material from being deflected up into the vacuum hopper filter Do not allow vacuum receivers with check valves to be over filled to a point above the bottom of the check valve Over filling prevents the check valve from sealing and creates a vacuum loss Adjust the conveying time on Time Fill systems to prevent this from happening Inspect periodically for erosion or wear Replace as required Figure 12 Typical Material Check Valve Pumps amp Conveying System Components Chapter 3 Installation 31 Installing A K or S 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 Atmospheric air from the vacuum line is introduced to the filter chamber equali
45. nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnanicins 54 Parts Department ssssssssssssseeeeeeene Error Bookmark not defined Service Department ssssssssssssssseeeee Error Bookmark not defined Sales Department sssssssssssssseeeee Error Bookmark not defined Contract Department ssessssssseeeee Error Bookmark not defined Pumps amp Conveying System Components v 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 The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the mechanical components of your conveying system We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustmen
46. nt inna a a ea eE aE aE nennen nennen nnne nnn NEEE ENE enne 23 3 2 Rigging and Placing Mechanical Components ccccccecceeeeeeeeeeeeeeeeeeaeeeeeeeeeess 24 Installing the Pump Packagt ooooococcccccocccccnconcnccncononcnnnonnnncnncononccnnonnnncnnonnancnncnnns 24 Installing the Control Panel ssssssssssssssssssssseee entere nn nnns 25 Installing Material Vacuum Tubing ooooooncccccnnncccnnnccnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 25 Installing FCA FCK or FCS Filter Chambers sessi eene 32 Installing Vacuum Receivers and Inventory Vacuum Receivers 34 3 3 Compressed Air Connections eesssssssssssssssseeeeeneee meme nere nnns 34 Making Pump Compressed Air Connections ooooocccccccccccocccnnncnnnnnncnnnononancnnnnnnnnns 34 3 A Electrical Connections Sio era e e a ea aaae n nennen enne ner nn nnns 34 Making Pump Power Drop Wiring CONNECtIONS coooocccccocconccccconcccnononananononnnnnnns 34 Making Control Panel Power Drop Wiring Connections eessssssssssss 35 Connecting the Control Panel to the Pump Package ooooococcccoccccccccccnccccnnnnaannnnnos 35 3 5 Initial Start up iiie c RR e RS ER RERO UE PA ER CERE NR LEX RERURR RETO CEXE ERREUR ER Yat E 36 Making Startup Checks esses nennen nnne nnna rn n nnne nennen naa 36 CHAPTER 4 OPERATION 1 eere enne nennen nnn nnn 37 4 1 Start Upsccce es
47. or take off adjustment Conveying times are too short Time Fill only See control panel s O amp I Vacuum line leak No material to convey Vacuum filter is plugged Dump Delay time set to zero or insufficient dump delay time Dusty material Dusty material Optional compressed air filter cleaning may be needed on filter chamber No material demand at receivers if none of the amber lights on the optional light board are lit The on line receivers are not assigned to the pumps that are on line Chapter 6 Troubleshooting Observe and time the hopper s when loading Note the time needed to fill a hopper Set the conveying time to a few seconds less Check proximity sensors for proper operation and proper wiring to PLC Repair Re set the conveying times to reasonable times Re adjust 1f needed Observe and time the hopper s when loading Note the time needed to fill a hopper Set the conveying time to a few seconds more Find and repair leak Make sure pickup probe 1s buried in material source Clean and or replace filter Set dump delay time to the time it takes the largest vacuum hopper in the system to dump Consult sales representative Consult sales representative Normal operation Pump packages shut off thirty 30 seconds after no demand is detected for the time programmed Reconfigure the control panel assigning the pumps to the desired hopper 43
48. particulates or is damaged by birds insects or small animals your warranty becomes void Any variance from these guidelines can cause excessive pump back pressure Such a condition can drastically affect equipment performance possibly leading to equipment damage Pumps amp Conveying System Components Chapter 3 Installation 24 Installing the Control Panel Select a flat vertical area for mounting the panel It should be in an area that gives your operator access to the control Consider how you are running wiring to the vacuum hoppers the filter chamber and pump motor starter s vacuum switch es and vent valve s The panel requires a low voltage grounded power drop as listed on the serial tag Note Avoid mounting control panel near material lines Installing Material Vacuum Tubing Well designed material vacuum piping systems provide the best conveying rates Vacuum material piping may be a single material line Y system or multiple material line or a combination of the two systems See figures 8 10 on page 26 and 27 for examples depending on the processing floor layout All systems utilize a common vacuum header line for all stations connected to a pump package material flow is controlled by sequence T or atmospheric valves operated by the control panel When installing material vacuum tubing take the following into consideration Vacuum leaks anywhere in the system reduce system capacity Keep the number of materia
49. placement Models 3 4 Pumps Centrifugal Models 4 O Air flow measured in cubic feet per minute cfm and cubic meters per hour cmh Note Rated performance is at standard atmosphere and sea level conditions High elevation affects system performance Pumps amp Conveying System Components Chapter 2 Functional Description 16 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 Figure 4 Typical Atmospheric Valves i 4 5 SEIS Pumps amp Conveying System Components Chapter 2 Functional Description 17 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 soleno
50. pply to the design and manufacture of automated equipment The Occupational Safety and Health Administration OSHA and the Joint Industrial council JIC are just a few of the organizations that have joined with the plastics industry to develop safety standards Every effort has been made to incorporate these standards into the design of the mechanical components of the conveying system however it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices Fail Safe Operation If a safety device or circuit should fail the design must be such that the failure causes a Safe condition As an example a safety switch must be a normally open switch The switch must be held closed with the device it is to protect If the switch fails it will go to the open condition tripping out the safety circuit At no time should the safety device fail and allow the operation to continue For example if a safety switch is guarding a motor and the safety switch fails the motor should not be able to run Safety Device Lock Outs Some safety devices disconnect electrical energy from a circuit The safety devices that are used on the mechanical components of the conveying system are primarily concerned with electrical power disconnection and the disabling of moving parts that may need to be accessed during the normal operation of the machines
51. r in valve 45 Problem Possible Cause Possible Remedy Vacuum line problem Disconnect the vacuum line at the first vacuum hopper and block it off The vacuum here should equal the vacuum at Pump package blower the blower Allow a few problem Use a cfm cfh seconds for vacuum to build monitoring device to ensure If the vacuum here is low that blower cfm cfh is to the disconnect the piping halfway manufacturer s specifications tO the first vacuum hopper and check the vacuum there If proper vacuum exists the problem is upstream If not work backward to isolate the Cont d vacuum loss e Tighten loose pipe couplers replace worn gaskets as needed Consult Service Engineer if problem persists Replace any damaged piping found Leaks in vacuum lines Check for leaks as described between valves in previous steps Vacuum conveying rate is declining due to a vacuum loss in the system Replace or re install worn or misaligned gaskets Hopper discharge flapper not sealing under vacuum Cont d E 1 Replace worn or missing gasket 2 Clean fouled flapper 3 Check counterweight for proper operation Repair or adjust as needed nternal check valves missing or damaged On single line Y systems internal check valves must be installed in the vacuum hoppers to seal all hoppers not being conveyed to If the check valves are present and undamaged they may be pushed too far onto
52. r motor combination Inspect periodically for proper tension and replace when worn Note V belts stretch when new Check belt tension after you have run them in At proper belt tension the belt should deflect downward 64 for every one inch span 1 mm every 6 4 cm from sheave to sheave Keep the pump package area clear of any debris that could be drawn through the vent valve and into the blower while the pump package is idling Torque the motor and blower sheave bolts to 72 ft Ibs 98 Nem Check the moisture traps in the compressed air lines Drain as needed Check the compressed air lubricator s for flow rate and level Use only 1 or 2 drops of oil per day when lubricating Adjust and fill as necessary Inspect the silencer periodically for contamination Silencer fouling indicates poor filter maintenance at the vacuum hopper or filter chamber Fines may also be drawn into the silencer through the pump package vent valve during the dump cycle from poor housekeeping near the pump package Caution Make sure you replace a contaminated silencer immediately to avoid blower damage and possible fire hazard Standard pump package TEFC motors do not require lubrication or oiling Optional motors may have different requirements Refer to the motor manufacturer s specification sheet in your Customer Information Packet Keep the control panel and pump package junction boxes securely closed to prevent component contamination Inspect a
53. res When you activate the controller the system energizes and initiates the conveying cycle The following components energize The vacuum pump motor starter The vacuum pump vent valve The sequencing valve above the first on line vacuum receiver that requires material The vacuum pump draws vacuum to that receiver When the receiver is full or the time interval elapses the controller then signals the atmospheric valve above the next on line receiver requiring material to energize allowing material to convey to that receiver The conveying sequence continues to the last on line vacuum receiver requiring material When the time interval for the last receiver elapses or the receiver is full a new conveying cycle begins at the first on line vacuum receiver requiring material Note The sequence of events listed above is a generalized description of what occurs when a controller is activated Consult your specific controller manual for an accurate depiction of these events Vacuum Switch VS Operation A high vacuum switch is mounted inside a pump package junction box It is preset to close at 14 Hg 475 millibars and is not adjustable The vacuum switch protects the pump package from motor damage caused by high amperage draw and strain on the blower Pumps typically draw a vacuum of less than 5 Hg 170 millibars only when air is pulled into the system and 8 to 12 Hg 271 to 339 millibars while conveying If system vacuum
54. t of the conveying system with your hands while it is running Before you start the conveying system check the following Remove all tools from the conveying system Be sure no objects tools nuts bolts clamps bars are laying in the area f your conveying system has been inoperative or unattended check all settings before starting the unit Atthe beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting Report the following occurrences IMMEDIATELY unsafe operation or condition unusual conveying system action leakage improper maintenance NEVER stand or sit where you could slip or stumble into the conveying system while working on it Pumps amp Conveying System Components Chapter 1 Safety 10 DO NOT wear loose clothing or jewelry which can be caught while working on the conveying system In addition cover or tie back long hair Clean the conveying system and surrounding area DAILY and inspect the machine
55. tall check valves on material inlet tubes inside vacuum receivers You can install a long or short radius bend on the last station where a Y tube is not needed Figure 8 Recommended Single Line Y Tube Installation Pumps amp Conveying System Components Chapter 3 Installation 28 Figure 9 Modified Single Line Y Tube Installation Figure 10 Manifold Y Tube Installation Pumps amp Conveying System Components Chapter 3 Installation 29 Figure 11 Typical Single Line Y Tube Installation Pumps amp Conveying System Components Chapter 3 Installation 30 Material Check Valves in Single Line Y Tube Systems 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 i
56. ts that should be followed before commencing with operation of the conveying system These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the conveying system safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that the mechanical components of your conveying system provide excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation t
57. zing the pressure inside the filter chamber The material discharge flapper valve falls open and dumps the fines and dust collected during the conveying cycle The K Filter Chamber utilizes compressed air as a means of filter cleaning The A Filter Chamber does the same except utilizes implosion cleaning The S is able to clean the filter by either method A compressed air filter cleaning blow back option is available for systems conveying very dusty materials Consult the Sales Department for more information Level and secure the filter chamber near the pump package Use s 9 mm bolts to anchor the filter chamber 1 Connect the piping between the vacuum inlet valve on the pump package and the tube stub on the filter chamber lid For easy filter maintenance install at least three feet 3 1 m of vinyl flex hose at the end of the run to the filter chamber The rest may be hard piping as long as it is properly supported 2 Run vacuum tubing from the tangential inlet tube to the vacuum header line servicing the vacuum hoppers Turn the inlet tube toward the header Support the tubing properly and make it vacuum tight Note Use of a system without a manufacturer approved filter system installed on the vacuum air inlet voids the blower warranty Pumps amp Conveying System Components Chapter 3 Installation 32 Figure 13 Filter Chamber Installation Optional Blowback Controller Shown
Download Pdf Manuals
Related Search