ACS A0571050 User Manual

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.

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. 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 dedicated to providing excellent customer service.

For immediate assistance, please contact:

• 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

• Mexico, Central & South America Email: acslatinamericacustserv@corpemail.com

• Europe, Middle East & Africa +48 22 390 9720

Email: acseuropecustserv@corpemail.com

• India +91 21 35329112

Email: acsindiacustserv@corpemail.com

• 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 are located. For more information, please visit us at www.acscorporate.com

United States:

ACS Schaumburg – Corporate Offices

1100 E. Woodfield Road Suite 588 Schaumburg, IL 60173 Phone: + 1 847 273 7700 Fax: + 1 847 273 7804

ACS New Berlin – Manufacturing Facility

2900 S. 160th Street New Berlin, WI 53151 Phone : +1 262 641 8600 Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP Suzhou, China 215126 Phone: + 86 8717 1919 Fax: +86 512 8717 1916

Europe/Middle East/Africa:

ACS Warsaw

Ul. Działkowa 115 02-234 Warszawa Phone: + 48 22 390 9720 Fax: +48 22 390 9724

India

ACS India

Gat No. 191/1, Sandbhor Complex Mhalunge, Chakan, Tal Khed, Dist. Pune 410501, India Phone: +91 21 35329112 Fax: + 91 20 40147576

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 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:

˛ Mechanical Components of Conveying System

˛ Bill of lading

˛ Packing list

˛ Operating and Installation packet

˛ Electrical schematic and panel layout drawings

˛ 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.

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.

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. A RMA 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.

Table of Contents

CHAPTER 1: SAFETY.................................................................... 6

1-1 How to Use This Manual ............................................................................................ 6

Safety Symbols Used in this Manual.....................................................................6

1-2 Warnings and Precautions .........................................................................................7

1-3 Responsibility............................................................................................................. 8

General Responsibility.......................................................................................... 8

Operator Responsibility ........................................................................................ 9

Maintenance Responsibility ................................................................................10

Reporting a Safety Defect...................................................................................10

CHAPTER 2: FUNCTIONAL DESCRIPTION .............................. 11

2-1 Models Covered in This Manual ...............................................................................11

2-2 General Description ................................................................................................. 11

Basic System Components.................................................................................11

Basic System Types...........................................................................................12

Equipment Cycle ................................................................................................12

2-3 Standard Features & Options ................................................................................... 12

Pumps ...............................................................................................................12

Atmospheric Valves............................................................................................16

Sequence T-Valves............................................................................................ 17

Filter Chambers.................................................................................................. 18

Pickup Tubes ..................................................................................................... 19

2-4 Safety Devices and Interlocks .................................................................................. 20

CHAPTER 3: INSTALLATION ..................................................... 22

3-1 Uncrating the Equipment.......................................................................................... 22

3-2 Rigging and Placing Mechanical Components .......................................................... 22

Installing the Pump Package ..............................................................................22

Installing the Control Panel................................................................................. 23

Installing Material/Vacuum Tubing ......................................................................23

Installing FCA, FCK, or FCS Filter Chambers ..................................................... 30

Installing Vacuum Receivers and Inventory/Vacuum Receivers...........................32

3-3 Compressed Air Connections................................................................................... 32

Making Pump Compressed Air Connections .......................................................32

3-4 Electrical Connections.............................................................................................. 32

Making Pump Power Drop Wiring Connections................................................... 32

Making Control Panel Power Drop Wiring Connections....................................... 32

Connecting the Control Panel to the Pump Package...........................................33

3-5 Initial Start-up........................................................................................................... 34

Making Startup Checks ......................................................................................34

CHAPTER 4: OPERATION .......................................................... 35

4-1 Start-up.................................................................................................................... 35

4-2 Operation Procedures .............................................................................................. 35

Vacuum Switch (VS) Operation ..........................................................................35

High Vacuum Relief Regulator Operation ........................................................... 36

4-3 Shut-down ............................................................................................................... 36

CHAPTER 5: MAINTENANCE.................................................... 37

5-1 Preventative Maintenance Schedule......................................................................... 37

5-2 Preventative Maintenance........................................................................................ 38

Maintaining Pump Packages ..............................................................................38

CHAPTER 6: TROUBLESHOOTING.......................................... 39

6-1 Introduction.............................................................................................................. 39

CHAPTER 7: APPENDIX ............................................................. 46

7-1 Warranty.................................................................................................................. 46

Warranty Specifications..........................................Error! Bookmark not defined.

Warranty Restrictions .............................................Error! Bookmark not defined.

Warranty Liabilities.................................................Error! Bookmark not defined.

Customer Responsibilities ......................................Error! Bookmark not defined.

7-2 Technical Specifications........................................................................................... 47

Annex B Information........................................................................................... 47

7-3 Spare Parts List ....................................................................................................... 48

7-4 Identification (Serial Number) Tag ............................................................................ 51

7-5 Technical Assistance ............................................................................................... 51

Parts Department ...............................................................................................51

Service Department............................................................................................51

Sales Department ..............................................................................................51

Contract Department ..........................................................................................51

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, preoperational 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 adjustments 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 that, 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.

Conveying System Safety Tags

Spraying Read Operation

Hazard and Installation

Manual

High Voltage Earth Ground

Inside Enclosure

PE Protected Earth

Lifting Point 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:

˛ 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 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.

1-3 Responsibility

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:

• 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 minutes 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.

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 out 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;

• If your conveying system has been inoperative or unattended, check all settings before

starting the unit.

• At the 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.

• 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 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. If there 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 connected 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.

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 for conveying pelletized, granular, or powder material in a central material handling system. A typical use is as an inplant 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

• 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.

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. 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 & Options

Pumps

5, 10 &15 Hp Positive Displacement

• Support base.

• Positive displacement blower.

• 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

• Sound enclosure.

• Premium-efficiency motors.

Figure 1: Positive Displacement Pump Dimensions

Unit size

Dimensions (inches)

hpABCDEF

5 10 15

27.5

85.822922

21.75

31.75

Unit size

Dimensions (cm)

kWABCDEF

3.75

7.5

11.25

847021874565581

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

Dimensions (inches)

hpABCDEFGH

3.5

26.25138.75

24.5137.53117.75

11.0

31.5

17.4

14.8128.6

17.75

35.5

Unit size

Dimensions (cm)

kWABCDEFGH

2.63

6733228946

4.84

6233197945

8.20

38804437302145 90

Figure 3: Pump Specifications

Model

Amp draw, full-load amps

Air flow Å

Line size

Ship weight

230 V

460 V

575 V

cfm

inches

lbs.

Pumps — Positive Displacement Models

Vacuum

Material

13.4

6.7

5.4

120

2.0”

385

28.4

14.2

11.4

200

2.5”

400

38.4

19.2

15.3

300

3.0”

420

Pumps — Centrifugal Models

Vacuum

Material

3.5

9.1

4.6

3.0

106

2.0”

1.5”

175

6.5

12.9

6.5

4.3

152

2.0”

300

32.5

16.2

10.6

225

2.5”

350

Model

Amp draw, full-load amps

Air flow Å

Line size

Ship weight

230 V

460 V

575 V

cmh

Pumps — Positive Displacement Models

3.75

13.4

6.7

5.4

204

50 mm

175

7.5

28.4

14.2

11.4

340

63 mm

181

11.25

38.4

19.2

15.3

510

76 mm

190

Pumps — Centrifugal Models

3.5

9.1

4.6

3.0

180

38 mm

6.5

12.9

6.5

4.3

258

50 mm

136

32.5

16.2

10.6

302

63 mm

159

Å 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.

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