Dekker HV450, HV140A, HV160, HV635, HV412XT Installation, Operation & Maintenance Manual
...
Installation
Operation
&
Maintenance
Manual
Rotary Piston Vacuum Pumps & Systems
SERIAL NO.:___________________________ September 2016
2
ROTARY PISTON VACUUM PUMPS & SYSTEMS
TABLE OF CONTENTS
CUSTOMER SERVICE ................................................................................................................................ 5
CONTACT INFORMATION ........................................................................................................................................................................ 5
ORDER INFORMATION .............................................................................................................................................................................. 5
INTRODUCTION ....................................................................................................................................... 6
SAFETY........................................................................................................................................................ 6
THEORY OF OPERATION ........................................................................................................................ 7
STORAGE .................................................................................................................................................... 8
INITIAL FREIGHT RECEIPT AND INSPECTION .................................................................................. 8
INSTALLATION ......................................................................................................................................... 8
UNPACKING ............................................................................................................................................................................................... 8
LIFTING ........................................................................................................................................................................................................ 8
LOCATION .................................................................................................................................................................................................. 9
MOUNTING................................................................................................................................................................................................. 9
VENTILATION/COOLING .......................................................................................................................................................................... 9
COOLING CAPACITIES AND PORT SIZES .............................................................................................................................................. 10
ELECTRICAL PREPARATION ..................................................................................................................................................................... 10
PIPE CONNECTIONS AND SIZING .......................................................................................................................................................... 10
INLET PIPING ............................................................................................................................................................................................. 11
DISCHARGE PIPING .................................................................................................................................................................................. 11
COOLING WATER PIPING (WATER COOLED SYSTEMS ONLY) ........................................................................................................... 12
ELECTRICAL CONTROLS (IF INCLUDED) ......................................................................................... 12
START UP PROCEDURES ...................................................................................................................... 13
BELT TENSION FOR V-BELT DRIVES....................................................................................................................................................... 15
SHUT DOWN PROCEDURE .................................................................................................................. 19
MAINTENANCE SCHEDULE ................................................................................................................. 20
DURING FIRST MONTH OF OPERATION ............................................................................................................................................... 20
EVERY DAY ............................................................................................................................................................................................... 20
EVERY 3 MONTHS .................................................................................................................................................................................... 20
EVERY YEAR .............................................................................................................................................................................................. 20
EVERY 5 YEARS ......................................................................................................................................................................................... 21
MAINTENANCE ....................................................................................................................................... 21
SEAL FLUID/OIL ........................................................................................................................................................................................ 21
OIL CHANGE PROCEDURE ..................................................................................................................................................................... 22
STANDARD SYSTEM CAPACITIES ............................................................................................................................................................ 22
OIL ANALYSIS ........................................................................................................................................................................................... 23
GAS BALLAST VALVE(S) ........................................................................................................................................................................... 23
OIL SOLENOID VALVE ............................................................................................................................................................................. 23
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
3
MOTOR BEARING LUBRICATION (WHERE REQUIRED) ........................................................................................................................ 23
MOTOR BEARING LUBRICATION SCHEDULE ........................................................................................................................................ 24
OPTIONAL ACCESSORIES .................................................................................................................... 25
TROUBLESHOOTING ............................................................................................................................. 25
START-STOP PROBLEMS .......................................................................................................................................................................... 25
VACUUM PROBLEMS ................................................................................................................................................................................ 26
OVERHEATING PROBLEMS....................................................................................................................................................................... 26
NOISE AND VIBRATION PROBLEMS........................................................................................................................................................ 26
OIL PROBLEMS .......................................................................................................................................................................................... 26
TROUBLESHOOTING QUICK REFERENCE GUIDE ................................................................................................................................. 27
WARRANTY, REPLACEMENT & RETURN POLICIES ........................................................................ 28
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
4
THIS INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL MUST STAY WITH
EQUIPMENT.
PLEASE REGISTER YOUR EQUIPMENT
WARRANTY AND START-UP RECORD ONLINE
AT WWW.DEKKERVACUUM.COM
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
5
CUSTOMER SERVICE
Contact information
935 SOUTH WOODLAND AVENUE, MICHIGAN CITY, IN 46360-5672
TEL: 219-861-0661
TOLL-FREE: 888-925-5444
24 HOUR SERVICE PHONE: 219-229-3587
FAX: 219-861-0662
Business hours: 7.30 a.m. – 4.30 p.m. CST
Website: www.dekkervacuum.com
E-mail: AfterSales_Support@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. Refer to the bill of lading or the gold-colored system information plate attached to
the system (see image below).
Gold-colored system information plate
Parts should be purchased from the nearest authorized DEKKER Vacuum Technologies, Inc. (hereafter
referred to as DEKKER) representative (visit www.dekkervacuum.com to find a distributor near you via the
Distributor Locator) or from the vacuum pump system supplier. If for any reason parts cannot be obtained
in this manner, contact the factory directly.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
6
INTRODUCTION
The DEKKER HullVacTM rotary piston vacuum pump has been designed for safe, reliable, trouble-free
service, provided the maintenance guidelines as set out in this manual are followed. Compared to other
vacuum pump systems, the HullVac rotary piston vacuum pump offers the advantages of no metal-to-metal
contact, low blank off pressures, high pumping speeds at low pressures, and durability. These pumps are
low maintenance and easy to use. However, 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. Please review and follow all instructions in this manual before attempting to install, start or
operate the equipment.
SAFETY
All vacuum pumps, systems and/or compressors (hereafter referred to as the Product) offered by DEKKER
have been designed and manufactured for safe operation. However, the responsibility for safe operation
rests with those who use and maintain these products. The safety department where the product is
installed should establish a safety program based on OSHA, federal, state, and local codes. It is important
that due consideration be given to hazards which arise from the presence of electrical power, hot liquids,
harmful gases, and rotating equipment. Proper installation and care of protective devices is essential to safe
system operation. These safety procedures are to be used in conjunction with the instructions contained in
this manual.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
7
THEORY OF OPERATION
The DEKKER HullVac rotary piston vacuum pump is designed and manufactured to achieve a high level of
performance. These pumps create a vacuum with a piston that moves in a circular path. As it rotates,
pressure is decreased on the inlet side and increased on the discharge side. The two sides are separated by
a film of oil between the piston and the cylinder. Once the piston makes a complete cycle, the clearance
volume is completely filled with oil, increasing the compression ratios within the pump. This design is what
gives rotary piston pumps their deep vacuum levels and durability. Depending on the application and desired
vacuum level, HullVac pumps are offered in single-stage or two-stage configurations. The two-stage pump
can obtain a deeper vacuum level because it utilizes two piston chambers in series.
Intake Stroke Discharge Stroke
Not suitable above 100 Torr Not suitable above 10 Torr
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
8
STORAGE
If the pump is to be stored in a location where freezing temperatures may be encountered, drain the water
jacket. The water jacket drain plugs are located on the exhaust side of the pump. Refill with antifreeze for
storage.
INITIAL FREIGHT RECEIPT AND INSPECTION
Before a system ships from DEKKER, it is thoroughly tested, and will not be released unless it passes
DEKKER’s Quality Control standards. Once the system is received and signed for in Good Condition,
DEKKER cannot be held accountable for undiscovered and/or unclaimed damage that is a result of freight
transit. It is the responsibility of the receiver to thoroughly inspect upon delivery. The customer should
take photos of the system as it arrives and send to DEKKER if there are any issues. Failure to report these
issues within the freight carriers’ undiscovered damage window can result in denial of warranty claims.
DEKKER does keep photos of all systems, as shipped, to assist in freight claims. Report any damage
immediately to AfterSales_Support@dekkervacuum.com.
Key items to check:
Is system received as requested? Are all parts, accessories, and components delivered?
Check the skid and crating for cosmetic damage. Was the skid or crating received in good condition?
Is there any cosmetic damage to the vacuum system or control panel?
Check wiring inside of control panel. All wires should be terminated and connections tight.
Control panel components should be tight on DIN rail or other mounts/fasteners.
Are there any leaks or puddles around the pump? Specify hose, piping or housing leak.
System must be given an initial startup test as soon as possible after delivery. This is to ensure that the
motor has not shifted out of alignment during transit as well as to verify that electrical components are
functioning without fault – Variable Frequency Drive (VFD), Programmable Logic Controllers (PLC), panel
cooling fans, transducers.
INSTALLATION
The design of the piping system, foundation layout, and plant location are the responsibility of the
purchaser. DEKKER Vacuum Technologies, Inc. and its representatives may offer advice, but cannot assume
responsibility for operation and installation design.
Please consult the factory or a specialist skilled in the design of plant layout, system piping design, and
foundation design. The installer should carefully read this manual before installing the equipment. DEKKER
or your local dealer can provide start up assistance in most instances for a fee. Contact DEKKER for
hourly/daily service rates.
Unpacking
Upon receipt of pump or system, immediately inspect for signs of damage. Carefully remove
packing or crating from around pump or system. Be sure to keep equipment in upright position.
Lifting
Lift the equipment carefully and with weight evenly distributed. DEKKER is not responsible for equipment
that has been damaged through mishandling, including being dropped. Use of DEKKER provided lifting
points will ensure proper handling.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
9
Location
Install the unit in a well ventilated and dust free area. The pump or system should be a minimum distance of
3 feet from surrounding walls and other equipment to allow for inspection, service, belt tightening, and oil
changes.
Mounting
The pump or system must be installed on a level surface. The foundation, typically a concrete pad, must be
designed to support the total unit operating weight, without any settlement or crushing. It must also be
rigid and substantial enough to absorb any equipment vibration, and must permanently support the system
baseplate or pump at all points. Mount the pump using concrete anchors.
If the pump is mounted to a baseplate, the baseplate must be leveled and secured with foundation bolts.
Foundation bolts must be of adequate size to withstand the mechanical stresses exerted on them. The
baseplate must be grouted if the total weight is over 5,000 lbs.
Ventilation/Cooling
Locate the vacuum system in an area with sufficient airflow and accessibility. To prevent excessive ambient
temperature rise, it is imperative to provide adequate ventilation. Cooling is an important aspect of reliable
equipment operation and it is therefore important to install the unit in a reasonably cool area where the
temperature does not exceed 104°F. For higher ambient temperatures contact the factory.
For water-cooled vacuum systems, it is necessary to check cooling water supply. A proper, consistent
water flow must be maintained for adequate cooling. Refer to the Cooling Capacities and Port Sizes table
on page 10 for recommended cooling water capacities at 40°F based on standard operation. A water miser
valve that automatically regulates water flow is recommended.
Water jacket pressure must not exceed 30 psig.
The water inlet and water outlet ports require National Pipe Thread (NPT) fittings and are located below
the vacuum inlet. Refer to the Cooling Capacities and Port Sizes table on page 10 for port sizes. The ports
are interchangeable, however if a water miser valve is installed it must be on the water outlet port.
Normal system operating temperature is between 140-160°F as measured on the oil solenoid valve body
located below the exhaust port. Pump casing temperature should not exceed 180°F. If excessive
temperature is measured, increase the cooling water flow. Maximum cooling water supply temperature
should not exceed 85°F.
Oil temperature should be maintained at 165°F. Minimum oil temperature should not be below 55°F. The
increased sealing oil viscosity caused by low temperature can lead to internal galling and motor overload
fault.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
10
Cooling Capacities and Port Sizes
Pump
Pump CFM
HP
Cooling Water
Capacities
(gpm)
Cooling Water
Port Sizes (Inch
– NPT)
HV55A
52 3 -
-
HV140A
130 5 -
-
HV160
150
7.5
1.5
1/2
HV412XT
300/340
10/15
2.5
1/2
HV450
450
20
3.5
3/4
HV635
635
30 5 3/4
HV850
850
40 7 1
HVC35A
32 3 -
-
HVC65
65 5 1
1/2
HVC100A
95 5 -
-
HVC180
180
10 2 1/2
HVC340
340
20
2.5
1/2
Electrical Preparation
All system wiring is performed at the factory if a control panel is supplied and mounted on skid. Check area
classification to ensure all electrical enclosures comply with code. Required customer wiring is minimal, but
should be done by a qualified electrician in compliance with OSHA, National Electric Code and all applicable
federal, state, and local codes concerning switches, fused disconnects, etc. DEKKER includes a wiring
diagram in the control panel for use by the installer. DEKKER recommends a main disconnect switch be
fitted between the vacuum system and the incoming power. Wire the motor using appropriate starters and
fuses to comply with local electrical codes.
All HullVac pumps are equipped with an oil flow solenoid valve that prevents oil from entering the
pumping chamber when the pump is not in use. Oil flow solenoid coil voltage should match the motor
voltage. The solenoid valve coil is energized whenever the motor is energized. During initial operation,
confirm valve operation by holding a screwdriver or other metal object close to, but not touching the valve
stem top. If the coil is energized, a gentle tugging or vibration will be detected. An oil stream will also be
present on the oil level site port whenever the pump is in operation. If an oil stream or splash is not
present, check the solenoid valve for proper operation.
After the electrical wiring connections are completed, check the incoming voltage to make sure the
incoming voltage is the same as the vacuum system voltage. Line voltage should be within the voltage
tolerance as specified on the motor. Check the system for proper motor rotation. The direction of rotation
is always counterclockwise when looking at the driven end and is marked by an arrow on the motor or
pump housing. Jog the motor by pressing the ON button and then the OFF button. If the rotation is
incorrect switch any two of the three main power leads on the contactor inside the control panel. Failure
to do so could result in serious equipment damage.
WARNING: Install, ground, and maintain equipment in accordance with the OSHA, National
Electrical Code and all applicable federal, state, and local codes.
Pipe Connections and Sizing
Before installation, remove all protective inserts on the pump suction and discharge. Piping connected to
the system must be installed without imposing any strain on the system components. Improperly installed
piping can result in misalignment, general operating problems, and pump failure. Use flexible connectors and
vibration isolators where necessary. Piping must be cleaned of debris before installation.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
11
Inlet Piping
Note: Install a temporary screen at the pump inlet flange at first start-up to protect the unit
against carryover of pipe debris and welding slag. The screen must be removed after the
initial run in period.
Inlet piping must be welded carbon steel that is vacuum rated and should be at least the size of the pump
inlet. Install the system as close as possible to the process to minimize losses due to the length of the
suction line. If the system has to be installed further away from the process, be sure the inlet piping is
properly sized to minimize the overall line pressure drop. For more information consult your dealer or call
the factory.
If the inlet gas pumped contains dust or foreign particles, a suitable 5 micron (or finer) inlet filter should be
installed at the inlet port. For more information consult your dealer or factory. A vacuum rated isolation
valve should be installed for routine blank-off performance testing and servicing.
Discharge Piping
DEKKER recommends, as a minimum, CPVC discharge piping as discharge temps may exceed +170°F.
CPVC is rated for 200°F max, and PVC is only rated for 140°F max. Discharge piping must be at least the
size of the pump exhaust port. Discharge piping should be routed outside or to a properly sized coalescing
filter. Install a drip leg with a tee on the discharge line to prevent condensables from draining back into the
pump. See the “Discharge Piping Diagram” as shown below. The drop leg volume should be such that it is
unlikely to fill with condensate between routine draining.
It is imperative that no flow restriction be present in the outlet line. Outlet flow restrictions lead
to excessive power consumption at high inlet pressure as well as overheating which may cause damage to
the pump.
Discharge Piping Diagram
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
12
Cooling Water Piping (water cooled systems only)
Water-cooled systems require an adequate supply of cooling water at a maximum of 40°F and a maximum
supply pressure of 30 psig. If the cooling water temperature or available pressure is higher, consult your
dealer or call the factory.
The cooling water outlet connection of the heat exchanger may be fitted with an optional water miser
valve, which regulates the cooling water flow rate depending on pump operating temperature. To raise the
system operating temperature, turn the valve-adjusting screw counter-clockwise when viewed from the
top. To lower operating temperature, turn clockwise. Normal system operating temperature is between
140-160°F. Minimum oil temperature should not be below 55°F.
ELECTRICAL CONTROLS (IF INCLUDED)
Disconnect Handles: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 Switch: Pump units will start in HAND mode (unless units are in
a shutdown alarm condition). The pumps will bypass vacuum setpoints. AUTO mode, allows units to
start based on vacuum setpoints.
Reset Button: The reset button is used to reset the starter overloads.
Audible Alarm: The audible alarm signals that the lag pump is in operation. The alarm can be
silenced by pressing the RESET pushbutton. The audible alarm may also be used to signal other alarm
conditions, such as high temperature, low oil level or high back pressure.
Alarm Silence Button: The alarm silence button is used to silence the audible alarm, but the light
will remain on unless alarm condition has been corrected.
Alarm Reset Pushbutton: The alarm reset pushbutton is used to reset an alarm condition when
the condition has been rectified.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
13
START UP PROCEDURES
1
Ensure all shipping plugs and/or paper covers are
removed from system and tagging information is
followed for successful startup.
2
Remove the belt guard and rotate the pump two
complete revolutions by hand in the
counterclockwise direction. This will clear
accumulated oil from the pump housing that can
collect during long inactive periods. Reinstall the
belt guard.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
14
3
Ensure sheaves are properly installed and aligned
before attempting to tension the drive. The V-belts
should be placed over the sheaves and in the
grooves without forcing them over the sides of the
grooves. Sheave alignment should be checked by
placing a straight edge across the sheave faces so
that it touches all four points of contact. A
misalignment of more than one-half of one degree
(one eighth inch in one foot) will adversely affect belt
life. Improper sheave alignment produces uneven
wear on one side of the belt, causes the belt to roll
over in the sheaves or throws the entire load on
one side of the belt, stretching or breaking the cords
on that side.
Avoid excessive heat (140°F and higher); belt life
will be shortened. Never switch or mix belts from
one groove to another on the sheaves. Do not use
belt dressing. Sheaves should remain free of oil and
grease. When replacing belts install an
identical set.
For more specific V-belt tensioning guidelines
consult factory.
Tensioning a Drive - General Rules of
Tensioning
1. Ideal tension is the lowest tension at which the
belt will not slip under peak load conditions.
2. Check tension frequently during the first 24-48
hours of run-in operation.
3. Over tensioning shortens belt and bearing life.
4. Keep belts free from foreign material which may
cause slip.
5. Make V-Drive inspection on a periodic basis.
Tension belt when slipping. Never apply belt dressing
as this will damage the belt and cause early failure.
Simple Tensioning Procedure
1. Measure the span length.
2. At the center of the span apply a force
(perpendicular to the span) large enough to deflect
the belt 1/64 inch, for every inch of span length. For
example, one deflection of a 100 inch span would be
100/64 or 1-9/16 inches.
3. Compare the force you have applied with the
values given in the Tensioning Table on page 15. If
the force is between the values for normal tension,
and 1-1/2 times normal tension, the drive tension
should be satisfactory. A force below the value for
normal tension indicates an under tensioned drive. If
the force exceeds the value for 1-1/2 times normal
tension, the drive is tighter than it needs to be.
4. After the proper operating tension has been
applied to the belts, double check the following: A)
Parallel position of the sheave shafts. B) Correct
alignment of sheave grooves.
V-Belt Adjustment
1. With all belts in their grooves, adjust centers
to take up the slack until they are fairly taut.
Use standard V-belt tensioning guidelines (see
opposite column).
2. Start the drive and continue to adjust until the
belts have only a slight bow on the slack side
while operating with load conditions.
3. After several days of operation, the belts will
seat themselves in the sheave grooves. Further
tensioning may be necessary to the point that
the drive shows a slight bow in the slack side.
Insufficient tension is often evidenced by
slipping (squealing) at start-up.
4. If the unit is idle for an extended period of
time, the tension on the belts should be
removed.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
15
Belt Tension for V-Belt Drives
V-Belt
Section
Small Sheave
Deflection Force (lbs)
For Drive Speed Ratios of:
Speed Range (RPM)
Diameter (in)
1.0
1.5
2.0
4.0+
A
1800-3600
3.0
2.0
2.3
2.4
2.6
1800-3600
4.0
2.6
2.8
3.0
3.3
1800-3600
5.0
3.0
3.3
3.4
3.7
1800-3600
7.0
3.5
3.7
3.8
4.3 B 1200-1800
4.6
3.7
4.3
4.5
5.0
1200-1800
5.0
4.1
4.6
4.8
5.6
1200-1800
6.0
4.8
5.3
5.5
6.3
1200-1800
8.0
5.7
6.2
6.4
7.2
AX
1800-3600
3.0
2.5
2.8
3.0
3.3
1800-3600
4.0
3.3
3.6
3.8
4.2
1800-3600
5.0
3.7
4.1
4.3
4.6
1800-3600
7.0
4.3
4.6
4.8
5.3
BX
1200-1800
4.6
5.2
5.8
6.0
6.9
1200-1800
5.0
5.4
6.0
6.3
7.1
1200-1800
6.0
6.0
6.4
6.7
7.7
1200-1800
8.0
6.6
7.1
7.5
8.2
Tensioning Table and installation image courtesy of Dodge PT Manual MN-4002
Notes:
1. Use approximately 130% of above values to tension a new set of belts.
2. Use closest sheave diameter for sizes not shown.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
16
4
Install a blank off flange to the inlet port or attach
to a sealed vacuum chamber. Make certain the
pump is attached to a closed system.
The discharge must be open to atmosphere
during startup. Excessive motor load
characterized by low rotation speed can be
experienced if the discharge is closed.
Repeated efforts to start the pump when the
discharge is not open to atmosphere may result in
motor and / or control system damage.
5
Jog the motor briefly and check direction of
rotation. The correct direction of rotation is
marked by an arrow on the motor or pump
housing. If direction is incorrect switch any two of
the three leads at the power connection. The
correct direction of rotation is counterclockwise
facing the pump from the drive end and clockwise
if viewed from the non-drive end.
6
Turn the cooling water on, if applicable.
7
Energize the motor – a slight belt slipping noise
may be heard as oil is pushed from the pumping
chamber through the valve deck. If the belt slip
noise does not stop within the first few seconds:
1. Stop the pump.
2. Disconnect the power.
3. Remove the belt guard
4. Rotate the pump once by hand.
5. Tighten the belts if needed.
6. Reinstall the belt guard.
7. Reconnect power.
8. Restart.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
17
8
Confirm the oil solenoid valve is open. The valve’s
solenoid coil is energized whenever the motor is
energized. During initial operation, confirm valve
operation by holding a screw driver or other
metal object close to, but not touching the valve
stem top. If the coil is energized, a gentle tugging
or vibration will be detected. An oil stream will
also be present on the oil level site port whenever
the pump is in operation. If an oil stream or splash
is not present, check the solenoid valve for
proper operation.
9
The oil level should be checked after the pump
has been operating at an inlet pressure below 1
torr for 5 minutes. Proper oil fill is confirmed
when the site port oil level is at least ½ level.
During initial evacuation, the site port oil level
may rise but will fall as the pump operates below
1 torr.
During operation, oil should always be visible in
the site port. If it is not, stop the pump and add
oil to the reservoir until it is visible around twothirds up the oil site port. An exact fill level is not
required as long as oil is always at least ½ level in
the site port, throughout all operating conditions.
An oil fill level above the site port should be
avoided as it will be difficult to verify correct fill
level and could damage the pump.
10
Check the voltage and motor current. They
should be within the specifications for the motor.
Note: This test should also be performed under
normal system operating conditions.
DANGER: HIGH VOLTAGE!
Lethal shock hazard present.
USE EXTREME CAUTION!
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
18
11
Test the pump for ultimate vacuum at the vacuum
inlet port. A vacuum gauge should then be
mounted to the vacuum break valve. Testing
should be accomplished before the pump is
permanently connected. This procedure will
establish a ‘benchmark’ for future reference. After
running for a few minutes, or until warmed up,
the pump should reach an ultimate pressure of 50
microns of mercury or less on a thermocouple or
equivalent type of vacuum gauge. If a Bourdon
type of vacuum gauge is used, it should read close
to 30 inches of vacuum.
12
After 15-30 minutes of operation, check pump
operating temperature, which should be in the
140-160°F range at the solenoid body. The casing
temperature will rise faster and be higher at
higher suction pressures. During any operation,
the casing should not rise above 180°F.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
19
SHUT DOWN PROCEDURE
1.
Close the system inlet isolation valve.
2.
Switch control power to OFF.
3
Open the gas ballast valves to vent the
pump to atmosphere. If system is
equipped with an automatic vent valve or
an anti-suckback valve, no action is
needed. Failure to vent the pump to
atmosphere may cause oil to fill into the
pumping chamber and travel back through
the inlet manifold into the vacuum process
chamber.
4
If water cooled, turn off the cooling water
supply.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
20
MAINTENANCE SCHEDULE
WARNING: Before attempting any maintenance such as changing the fluid, disconnect all
power from the system by switching off the main breaker or disconnect switch. This will
prevent the system from automatically starting from a vacuum switch.
To help ensure trouble free system operation, a basic maintenance schedule consisting of the following
system checks is recommended.
During First Month of Operation
Check belt tension weekly.
Verify tightness of pump mounting bolts weekly.
Torque the side cover bolts at the end of first month of operation to 45 foot-pounds.
Every Day
Check oil level daily - oil level should be between 1/2 and 2/3 level in the site port while in operation.
Check pump temperature daily - casing temperature should not exceed 180°F.
Every 3 Months
Check belt tension.
Verify tightness of pump mounting bolts.
Every Year
Remove the oil reservoir access plate. Clean and inspect the sump for signs of metal filings that may be
an indication of excessive internal wear. Strain the oil through a mesh bag to inspect for particulates.
Remove the oil / air separator and the valve deck cover. Verify the valves are intact and free to move
up and down. Examine for signs of excessive wear.
If needed, replace the valve deck springs and wear plates.
Examine the belts for signs of excessive wear and replace as needed.
Verify if motor lubrication is required for pump motor.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
21
Every 5 Years
Container Size
Standard
Water Application
1 Gallon Container
5120-0010-002
5120-0010-003
5 Gallon Container
5120-0050-000
5120-0050-008
55 Gallon Drum
5120-0550-000
5120-0550-002
Replace the bearings, shaft seals, shaft seal wear sleeves, and o-rings.
Replace the oil flow solenoid valve wear components.
Replace the gas ballast valves.
MAINTENANCE
WARNING: Before attempting any maintenance such as changing the fluid, disconnect all
power from the system by switching off the main breaker or disconnect switch. This will
prevent the system from automatically starting from a vacuum switch.
Seal Fluid/Oil
The product(s) are shipped with DEKKER’s specially formulated HullVac seal fluid (hereafter referred to
as oil). DEKKER recommends that this oil be used to obtain the ultimate performance from the HullVac
product and to maintain the 3-year warranty period.
Oil should be changed whenever it appears white or yellow, foams consistently, or when dirty. Oil change
frequency depends on the materials being pumped. For clean operation, oil should be changed every 3000
operating hours or every 9 months, whichever comes first. For other operation, oil change could range
from once or twice a week or less dependent upon the type of application.
The most common contamination is water in the oil and can be recognized by a milky appearance visible in
the site port. Closing the pump inlet valve and operating the gas ballast valves for 2 to 4 hours can remove
this water. If this does not clear the oil, change it. In applications with consistent water accumulation,
draining the water from the reservoir prior to operation is recommended.
HullVac Oil
Safety Data Sheets (SDS) available upon request.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
22
Oil Change Procedure
System
Capacity (gal)
HV55A
0.9
HV140A
3.3
HV160
4
HV412XT
12
HV450
13
HV635
15
HV850
25
HVC35A
0.9
HVC65
2.5
HVC100A
3.3
HVC180
6.5
HVC340
20
Run the pump until normal operating temperature is achieved. (140-160°F as measured on the oil solenoid
valve). Run the pump for at least 1 hour prior to draining the oil. This will warm the oil to facilitate faster
and more complete draining. CAUTION: OIL WILL BE HOT!
Follow these steps to drain the oil:
Disconnect main power to pump.
Vent the inlet to atmosphere for 10 to 15 seconds. This will force the oil from the lower pumping
chambers into the upper reservoir.
Open the oil drain valve and allow the oil to drain completely.
Close the oil drain valve and rotate drive belts by hand with the inlet open to atmosphere for 5 – 10
rotations, then open the drain valve again to scavenge residual oil. This will force residual oil from the
pumping chamber into the oil reservoir where it can be drained.
Follow these steps to fill with new oil:
Close the oil drain valve and fill the reservoir to the 2/3 site-port level by pouring oil through the oil
fill port located on top of the pump.
Reconnect main power to pump.
Close the inlet isolation valve so that the pump is blanked-off. Run the pump for 2-3 minutes. Check
the oil level.
Add oil until the site port level is between 1/2 and 2/3 level in the site port. If overfilled, open drain to
drain off excess and re-run unit to confirm oil level.
The approximate oil capacities are given in the Standard System Capacities table below.
Standard System Capacities
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
23
Oil Analysis
DEKKER offers oil analysis to customers, regardless of the age of their system. Collect approximately 1 pint
from the machine in a clean bottle of any type and secure it. On the bottle and/or a packing list, please
include the following: system serial number, the type of oil, the run hours on the oil and machine, and note
any problems you are having with the system if applicable, as well as the system process conditions.
Also make sure to provide contact information along with an email address. After the analysis is complete,
DEKKER will provide a report of the condition of the oil, along with recommendations.
Send to:
DEKKER Vacuum Technologies, Inc.
935 S. Woodland Ave.
Michigan City, IN 46360
United States
ATTN: After Sales
Gas Ballast Valve(s)
The gas ballast is a method of operating the pump to help prevent vapors from condensing into liquids in the
pump oil. Properly applied, it works well with water vapor and reasonably well with some other condensable
vapors. The drawback of using the gas ballast is that it will limit the ultimate vacuum the pump can attain. To
engage, open one or both ball valves depending on the degree of ballasting required to clear the condensable
contamination from the oil supply. There will be a slight change in the sound of the pump and the base
pressure will rise slightly. Excessive heat will be generated when the valves are open and care must be given to
ensure adequate cooling water flow. Be sure the pump body temperature does not exceed 180°F as measured
on the casting surface below the sight port.
Oil Solenoid Valve
The oil solenoid valve located under the exhaust port prevents oil from filling into the pumping chamber when
the pump is turned off or when there is a power failure. It is critical that this valve operates properly. If
the valve malfunctions in an open position, oil will flow back into the pumping chamber when the pump is shut
off. This will result in hard starting, excessive belt wear, and possible equipment damage.
If the valve is stuck in the closed position, poor vacuum performance will result. If the pump is operated for
longer than a minute without oil, internal damage may occur. The condition of the solenoid valve interior will
mirror the condition of the oil reservoir housing. If there is a buildup of sludge, varnish, or particulate in the oil
reservoir, the solenoid valve body may be likewise contaminated.
Motor Bearing Lubrication (where required)
The motors are shipped from the factory with the bearings properly packed with grease. After extended
storage of 6 months or greater, the ball bearings should be re-lubricated prior to starting with a good quality
high temperature lithium based grease of #2 consistency. Typical products are Texaco Premium RB and
Chevron SR1 #2. Roller-bearings (V-belt drive systems) use the Texaco Premium RB or Chevron Black Pearl
EP #2.
The bearings may be lubricated with the motor running or stationary. Stationary with the motor warm is
preferred. Locate the grease inlets; there is one on each end of the motor.
Note: This is generally the case with domestic motors. European motors use sealed bearings and do not
require lubrication. Consult factory with any questions.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
24
Clean the area and replace the pipe plug with a grease fitting (as generally they are not equipped with a grease
Lubrication Frequency – Ball Bearings
Roller bearings - divide time by 2
NEMA
Frame
Standard
Conditions
Severe
Conditions
Extreme
Conditions
182-215
3 years
1 year
6 months
254-365
2 years
6-12 months
3 months
404-449
1 year
6 months
1-3 months
ALL
6 months
3 months
1 month
Lubrication Volume
NEMA
Frame
Volume
(Cubic Inches)
182-215
0.5
254-286
1
324-365
1.5
404-449
2.5
fitting). Remove the grease drain plug, located at the lower portion of each motor face (typically a plastic plug),
and loosen any hardened grease that may block the drain. Add the recommended volume of the previously
described grease using a hand operated grease gun. Run the motor for 2 hours. Replace the pipe plug in grease
drain.
Mixing of lubricants is not recommended due to possible incompatibility. One of two things may happen if
incompatible greases are mixed: (1) the mixture could harden and not release any of the oil; (2) the mixture
could soften, releasing all of the oil. When changing lubricants, be sure to grease and then re-grease after 100
hours of service.
Frequency/volume of greasing is based on service conditions, speed and frame size. See the Motor Bearing
Lubrication Schedule table below.
Standard conditions: 8 hour day operation, normal or light loading, clean environment at a 100ºF maximum
ambient temperature.
Severe conditions: 24 hour operation or shock loading, vibration, dirty or dusty environment.
Extreme conditions: heavy shock, vibration, or dust. See the Motor Bearing Lubrication Schedule table
below for lubricating details.
Motor Bearing Lubrication Schedule
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
25
OPTIONAL ACCESSORIES
The following accessories are available for HullVac rotary piston vacuum pump systems.
Automatic Inlet Vent Valve: Includes a normally open solenoid valve and filter assembly mounted
to the pump inlet port. When power is shut off, the pump inlet and manifold will be vented to
atmosphere. This will prevent accidental oil suckback into the manifold and process chamber and will
also vent the chamber up to atmosphere.
Automatic Inlet Isolation Valve: Consists of a pneumatically actuated ball valve mounted on the
pump inlet that automatically closes whenever power is shut off. Note: This includes the
automatic inlet vent valve.
Temperature Control Valve: Reduces cooling water flow by up to 90% while it controls pump
operating temperature within the optimal range of 140-165°F. This temperature optimizes water and
solvent evaporation from the oil supply while preventing damage due to excessive heating.
Inlet Filter: Traps particulate larger than the internal clearances of the pump (5 micron). Must be
installed horizontally.
Oil Mist Eliminators: Strips atomized oil droplets from the exhaust stream, reducing the
appearance of smoke. Assembly comes complete with a ball valve on the canister drain and a 0 to 15
psig gauge to monitor filter element condition.
TROUBLESHOOTING
The following is a basic troubleshooting guide. Please consult the factory for advanced troubleshooting.
Each HullVac system is tested and checked at the factory. Always indicate system model and serial number
when calling.
WARNING: Before attempting any repairs, disconnect all power from the system by
switching off the main breaker or disconnect switch. All electrical work should be done by a
qualified electrician in compliance with OSHA, National Electric Code and any other
applicable local electrical code.
Start-Stop Problems
System will not start in HAND or AUTO position:
1. No main AC power. Confirm that the main AC power disconnect is ON and supplying power to the control
panel. This can be measured with an AC voltmeter at the power supply terminals in the control panel. Refer to
the electrical control panel diagram supplied with the system. If main AC power is not present at the power
supply, verify incoming AC voltage on the motor contactor.
2. Check if the disconnects or circuit breaker is switched on.
3. Check the overload setting on the starter.
4. Check all fuses.
5. Ensure that the proper voltage is supplied and that the wire size is correct.
6. Check electrical control panel (if installed) and make sure that all of the wires are tight. Wires may vibrate
loose during shipment or operation.
7. Check oil level. Add oil to reservoir if needed.
8. Check if the pump has seized by removing the belt guard and rotating the belts by hand (disconnect
power first). If a rubbing noise or binding is observed, contact the factory.
System shuts down while running:
1. Check oil temperature. Normal system operating temperature is between 140-160°F as measured on the oil
solenoid valve body located below the exhaust port.
2. Ensure that the proper voltage is supplied and that the wire size is correct.
3. Check for loose electrical connections.
4. Check if the pump has seized by removing the belt guard and rotating the belts by hand (disconnect
power first). If a rubbing noise or binding is observed, contact the factory.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
26
Vacuum Problems
System operates, but does not achieve desired vacuum level:
1. Stop system and disconnect power.
2. Check if the inlet valve is open and inlet filter (if equipped with filter) is clean.
3. Ensure that no lines are open to the atmosphere, causing loss of vacuum.
4. Check for leaks in piping systems, using conventional leak detection methods.
5. Ensure that the oil level is correct.
6. Check if the oil solenoid valve is working.
7. Check if the motor rotation is correct. The correct direction of rotation is counterclockwise facing
the pump from the drive end and clockwise if viewed from the non-drive end. If incorrect, switch any
two of the three main power leads.
Overheating Problems
System overheats or operates above 180oF:
1. Stop system and disconnect power.
2. Check if the oil solenoid valve is working.
3. Ensure that the oil level is correct.
4. Verify cooling water flow, if applicable.
5. Verify ambient air temperature is 104°F or below.
Unit overheats on start-up in low ambient temperatures:
1. Stop system and disconnect power.
2. Verify oil temperature. Oil tends to thicken in temperatures of 55°F and below.
Noise and Vibration Problems
The system is making an abnormal noise or sound:
1. Stop system and disconnect power.
2. Check belt tension and alignment.
3. Ensure that the oil level is correct.
4. Check the inlet filter (if equipped with filter) and clean if necessary.
5. Check if the inlet valve is closed.
System is vibrating excessively:
1. Stop system and disconnect power.
2. Check belt tension and alignment.
3. Check if baseplate is properly supported. Uneven floor will distort baseplate, which could cause
vibrating problems.
4. Check that the mounting bolts of pump are not loose. Tighten as required.
Oil Problems
System uses excessive oil or produces an oil-mist:
1. Ensure that the pump is pulling a deep vacuum level (deeper than 100 torr for single-stage and 10 torr
for two-stage).
2. Stop system and disconnect power.
3. Confirm oil level is not too high.
4. Confirm that pump is using factory recommended oil.
5. Ensure that discharge piping is arranged correctly.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
27
Troubleshooting Quick Reference Guide
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
28
WARRANTY, REPLACEMENT & RETURN POLICIES
DKR_KNOW_GEN_09_rev2
Warranty policy for DEKKER vacuum pumps, systems and/or compressors (hereafter referred
to as the Product)
DEKKER Vacuum Technologies, Inc. (hereafter referred to as DEKKER) 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.
DEKKER warranty is from date of shipment, provided the DEKKER Products have been operated
exclusively with DEKKER seal fluid (where noted) and have been operated during the full warranty period
as per the instructions given in the Installation, Operation, and Maintenance (IOM) Manual. If purchaser
elects to use a non-DEKKER seal fluid, which has been approved by DEKKER, product warranty may be
reduced (as noted below). If purchaser elects to use a non-DEKKER seal fluid, which has NOT been
approved by DEKKER, product warranty may be void.
3-Year Warranty
Vmax systems: 3-year warranty with DEKKER Vmaxol seal fluid; 2-year warranty with non-DEKKER seal
fluid
HullVac pumps and systems: 3-year warranty with DEKKER HullVac seal fluid; 2-year warranty with
non-DEKKER seal fluid
2-Year Warranty
DuraVane pumps, systems and compressors: 2-year warranty with DEKKER Duratex seal fluid;
18-month warranty with non-DEKKER seal fluid
TiTan liquid ring vacuum pumps and compressors: 2-year warranty
Maxima-C and Maxima-K liquid ring vacuum pumps: 2-year warranty
AquaSeal systems: 2-year warranty
ChemSeal systems: 2-year warranty
1-Year Warranty
MTH
Vmax
seal fluid
All other systems not specified above: 1-year warranty
All custom-engineered systems: 1-year warranty
6-Month Warranty
Rebuilt pumps and systems: 6-month warranty
Ninety (90) Days
Mechanical shaft seals: Ninety (90) day warranty
systems: 1-year warranty with DEKKER Vmaxol seal fluid; 1-year warranty with non-DEKKER
All 3rd party components are subject to Manufacturers’ Warranty.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
29
WARRANTY, REPLACEMENT & RETURN POLICIES
DKR_KNOW_GEN_09_rev2
The replacement of maintenance items including, but not limited to oil, seals, bearings, filters, vanes in
rotary vane pumps, etc., made in connection with normal maintenance service are not covered under this
warranty.
No warranty shall apply to products that have been misused or neglected, which includes operation in
excessive ambient temperatures, dirty environments or the pumping of corrosive, erosive or explosive
liquids or gasses or for problems caused by a build-up of material on the internal parts of the product.
Under this warranty the purchaser is entitled to the repair or replacement (whichever DEKKER elects) of
any part or parts of the product which do not conform to specifications. This warranty shall be void unless
said nonconformance is discovered before the expiration of this warranty. For repairs, DEKKER must be
notified in writing, a Return Merchandise Authorization (RMA) must be obtained and the nonconforming
part(s) need to be returned to DEKKER, transport charges prepaid, within thirty (30) days of discovery.
Repairs shall be made at DEKKER’s facility without charge, except for return transport charges.
Replacement parts provided under the terms of this warranty are warranted for the remainder of the
warranty period applicable to the product in which they are installed, as if such parts were original
components of that product.
No allowance will be granted for repairs or alterations made by the purchaser without the DEKKER’s
written consent.
In lieu of the foregoing remedy, DEKKER may (if DEKKER so elects), redesign and/or replace the product
or refund the full purchase price thereof.
If purchaser disassembles the product for any reason without the written consent of DEKKER, this
warranty shall be void.
Limitation of liability for DEKKER vacuum pumps, systems and compressors:
DEKKER’s obligations are limited to repair, redesign, replacement or refund of the purchase price, at
DEKKER’s option. In no event shall the purchaser be entitled to recover incidental, special or consequential
damages arising out of any defect, failure or malfunction of the product.
This warranty and DEKKER’s obligation there under is expressly in lieu of all other warranties, including but
not limited to the implied warranties of merchantability and fitness for a particular purpose. All warranties
which exceed the aforementioned obligations are hereby disclaimed by DEKKER and excluded from this
warranty. No other person is authorized to give any other warranty or to assume any other liability on
DEKKER’s behalf without written authorization.
Replacement Policy (Product Failure) for DEKKER vacuum pumps, systems and/or
compressors
(hereafter referred to as the Product)
DEKKER Product failures must be reported directly to DEKKER immediately. Product must be returned
to DEKKER factory for warranty consideration, unless field service is Pre-Authorized by DEKKER. The
product will be evaluated for defects in workmanship and materials. Under no circumstance will product
be considered for immediate, no-charge replacement without substantial evidence of material defect or
assembly error.
User error, incorrect supply voltage, or damage incurred as a result of mishandling will not be honored.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
30
WARRANTY, REPLACEMENT & RETURN POLICIES
DKR_KNOW_GEN_09_rev2
Product failures will require a purchase order (in the original dollar amount of damaged/failed product)
from the distributor or direct customer to release the replacement pump or product. A Return
Merchandise Authorization (RMA) number will be generated by a DEKKER After Sales Associate and issued
to the distributor or customer to return the original product. The product will undergo a thorough
evaluation upon receipt and credit will be issued in full if the failure is determined to be warrantable. If
failure is determined not to be warrantable, the purchase order will be charged for the replacement
product.
DEKKER does not cover expedited shipping in any circumstance.
Motor failures will be determined warrantable based on the evaluation of the motor manufacturer or their
authorized representative. Please contact DEKKER for assistance with finding your motor manufacturer’s
local authorized repair center.
Return Policy for DEKKER vacuum pumps, systems and/or compressors (hereafter referred to as
the Product)
Return for Credit (product not needed):
Distributor or direct customer will request an RMA number from DEKKER After Sales Associate and
return the product pre-paid. Collect freight or parcels will be refused unless prior approval is given by
After Sales Associate.
A minimum 15% restock fee applies. If product is damaged by customer, as a result of mishandling or poor
packaging for return shipment, this fee may be increased as determined by DEKKER.
Return for Replacement (incorrect part number received due to DEKKER shipping error):
New purchase order is required to release correct items. DEKKER After Sales Associate will issue RMA
for incorrect items. Upon receipt, if product is returned in good condition, the original order will be
credited in full.
Return for Replacement (customer ordered incorrect part):
New purchase order is required to release correct items. DEKKER After Sales Associate will issue RMA
for incorrect items. Upon receipt, original order will be credited less minimum 15% restock fee. If product
is damaged by customer, as a result of mishandling or poor packaging for return shipment, this fee may be
increased as determined by DEKKER.
Return for Replacement (damaged product received):
Photos should be taken immediately upon discovery of damage to assist in a claim with the shipping
company. A new purchase order is required to release replacement items. Once items are received at
DEKKER, they will be evaluated for repair/replacement and liability determined with shipping company. It
is the discretion of the receiver to refuse any shipment. If you have any questions or concerns, contact a
DEKKER After Sales Associate.
DEKKER Vacuum Technologies, Inc. – HullVac / September 2016
Loading...