Installation Operation and Maintenance Manual Lubricated and lubricated for saturated air (wet) service rotary vane vacuum pumps and systems SERIAL NO:___________________________ Feb 2008/07
LUBRICATED ROTARY VANE VACUUM PUMPS AND SYSTEMS TABLE OF CONTENTS INTRODUCTION Safety STORAGE INSTALLATION Unpacking Lifting Location Mounting Ventilation Electrical preparation Pipe connections and sizing Inlet piping Discharge piping THEORY OF OPERATION Pump lubricant Pumps for saturated air (wet) service Gas ballast valve Oil capacity table START-UP PROCEDURES SHUT-DOWN PROCEDURES SEQUENCE OF OPERATION SYSTEM ALARM CONDITIONS NFPA 99 MAINTENANCE Pump oil level Oil change Devarnishing Oil filter (if insta
INTRODUCTION DuraVane rotary vane vacuum pumps and systems haven been designed to give you safe, reliable and trouble-free service, provided some of the basic maintenance guidelines as set out in this manual are followed. A vacuum pump is a rotating piece of equipment and operators must exercise good judgment and follow proper safety procedures to avoid damage to the equipment or personal injury.
The number and location of shims will be determined by the design of the baseplate. Firm support should be provided at points where weight will be concentrated at the anchor bolt locations. Use enough, and large enough shims to provide rigid support. Baseplates are usually designed with openings to allow pouring grout. When the baseplate has been shimmed and leveled, and the anchor bolts have been snugly tightened, a dam is constructed around the foundation to contain the grout.
Discharge Piping Do not discharge the exhaust gases from the pump or system into the area where the system is installed. Vapors pulled over from the process could be hazardous. Discharge piping should be at least the size of the pump discharge. DEKKER recommends the installation of a dripleg with tee on the discharge line, to prevent any condensed vapors discharged by the pump from draining back into the pump oil reservoir. See diagram below.
Pump Lubricant All pumps are shipped without oil. A charge of our factory recommended Duratex lubricant is shipped in a separate container with each pump. Before filling the pump with oil, check that the pump is installed level. Fill the pump with the recommended lubricant (see “Oil capacity table” below) through the oil fill plug until it reaches the 1/2 way mark of the sight glass. WARNING: Do not overfill the pump. Do not add or fill oil when the pump is running.
Oil capacity table Use the table below for oil capacities and containers of Duratex oil available: Pump Model Oil Capacity Container Standard (1000 hour life) Synthetic – Long Life (2000 hour life) Duratex oil quart liters size Oil Oil RVL002H DURATEX 32 0.06 0.06 1 quart 1 gallon 5210-0002-004 5210-0010-004 5210-0002-005 5210-0010-005 RVL003H DURATEX 32 0.06 0.06 1 quart 1 gallon 5210-0002-004 5210-0010-004 5210-0002-005 5210-0010-005 RVL006H DURATEX 32 0.25 0.
START-UP PROCEDURES 1 DuraVane rotary vane vacuum pumps and systems are shipped from the factory dry. They do not contain oil. A container of Duratex oil is shipped with the unit. Before operating add the supplied oil to the pump(s). Fill the pump(s) to the middle of the sight glass before start-up. 2 Completely close the inlet suction valve before starting the unit.
SHUT-DOWN PROCEDURE To stop the vacuum pump unit, press the STOP button. A built-in anti-suck-back valve will prevent oil from the oil reservoir being sucked back into the pump cylinder. SEQUENCE OF OPERATION The following sequence of operation is a description of how the DuraVane rotary vane vacuum pump system should operate. The description is general to cover simplex to multiplex (more than one pump) systems. It is assumed that all start-up procedures have been followed.
SYSTEM ALARM CONDITIONS NFPA 99 The following is a description of how alarm conditions will affect the operation of medical systems compliant to NFPA 99. If a “Lag pump in operation” alarm is installed in the panel, observe the following. Such an alarm is standard with medical packages. The alarm consists of a warning light and an audible alarm. The alarm will trigger when the “lag” pump starts up. The alarm will not affect the operation of the system. The light will illuminate and the alarm will sound.
Devarnishing The operating life of the pump is greatly enhanced based on the oil quality and condition of filters. Oxidized or darkened oil is a sign of trouble. Plugged filters reduce performance and may damage pump. Periodic maintenance will offer the best protection for your equipment. DEKKER offers a specially formulated devarnishing compound Proclean 68D for rotary vane vacuum pumps and systems. Procedure for using Proclean 68D and MSDS sheet, are included with the product.
Mixing of lubricants is not recommended due to possible incompatibility. Signs of incompatibility are extreme soupiness from the grease relief drain or from the shaft opening. If changing a lubricant, grease and then re-grease after 100 hours of service. Frequency/volume of greasing is based on service conditions, speed and frame size. See tables below. Standard conditions: 8 hour day operation, normal or light loading, clean environment at a 100 ºF maximum ambient temperature.
ELECTRICAL CONTROLS (if included) Disconnect Handles: must be turned on to energize the system. The handles must be turned off to open control panel. CAUTION: High voltage, main disconnect must be off when servicing panel. HOA (Hand-Off-Auto) Selector Switches: are supplied only if vacuum switches are supplied. Pump units will start in HAND mode (unless units are in a shutdown alarm condition). The pumps will bypass vacuum switches. AUTO mode, allows units to start upon contact closure of the vacuum switch.
Inlet Filter (standard on systems): An inlet filter is installed as standard on the DuraVane rotary vane vacuum pump systems. For pumps only, an inlet filter is optional but recommended and needs to be installed in the inlet piping. Vacuum Relief Valve (optional): This valve may be installed on the pump suction manifold or on the receiver. The vacuum relief valve is used to maintain a certain vacuum level.
increase the life expectancy of the system. If the demand for the remaining pumps needs to change, you must enter the necessary value in the Controller for the level of vacuum you wish to maintain as a minimum/maximum for each on/off switch point. If there is not a demand for the lag pump(s) they will never run with the lead pump. Every day the lead pump will change. When the lead pump cannot handle the demand of the system, the remaining pump(s) will turn on.
Vacuum pump ON/OFF settings for Microprocessing Controller (Vacuum in “Hg): When setting the ON and OFF switch points in your Controller, use the following table for reference: Inches of HgV PLC Setting 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 234 488 742 996 1250 1504 1758 2012 2266 2520 2775 3028 3282 3536 3790 4044 4298 4552 4806 5060 This table will apply to all single and multiplex systems equipped with a Controller after 5/15/02 (all units supplied with a Controller prior to this
Protective Devices The following protective devices are available to protect the unit from being damaged and to help with maintenance. High Temperature Switch (optional): will signal when the temperature of the oil is exceeding the recommended level. The switch will shut the unit down. The unit will not restart until the alarm condition is acknowledged and is reset. The switch is a “snap disc” type of switch that is normally closed. When the temperature reaches the maximum setpoint, the switch will open.
TROUBLESHOOTING Following below is a basic troubleshooting guide. We recommend that you consult your local dealer for service. Each DuraVane rotary vane vacuum pump unit is tested and checked at the factory. Always indicate unit model and serial number when calling. WARNING: Before attempting any repairs, disconnect all power from the unit by switching off the main breaker or disconnect switch. This will prevent the unit from automatically starting from a vacuum switch.
11. Check to see if inlet check valve assembly is stuck in closed position due to contamination. Disassemble and clean inlet check valve and screen as required. 12. Check back-pressure on pump. Exhaust element may need to be replaced. Refer to Installation and Operations manual for maximum pressure and replacement instructions. 13. Internal parts may be worn or damaged. Contact authorized dealer. 14. One or more of the vanes in the rotor may be stuck. Contact authorized dealer.
2. 3. 4. 5. Check if motor rotation is correct by comparing it to the arrow on the motor or pump housing. If incorrect switch any two of the three main power leads on the contactor (3-phase only). Check bearings. If bearings are noisy, contact authorized dealer for replacement instructions. Foreign particles may have carried over into the pump, causing damage to the vanes or other internal parts. Contact authorized dealer. One of the vanes in the rotor may be stuck.
935 SOUTH WOODLAND AVENUE, MICHIGAN CITY, IN 46360-5672 TEL.: 219-861-0661 – FAX: 219-861-0662 – TOLL-FREE: 888-925-5444 Business hours: 7.30 a.m. – 4.30 p.m. CST Website: www.dekkervacuum.com E-mail: Info@dekkervacuum.com Sales@dekkervacuum.com Techsupport@dekkervacuum.com Order information When calling for service, parts or system information always have the pump or system model number and serial number(s) ready.
WARRANTY POLICY Warranty policy for DEKKER vacuum pumps and systems: April 2006 DEKKER Vacuum Technologies, Inc. (hereafter referred to as the Company) warrants that the products hereunder shall be free of defects in material and workmanship and conform to the specifications given in connection with the sale of the product.
