Idex Corken Coro-Vac CPS1X, Corken Coro-Vac CPS1V, Corken Coro-Vac CPS6R, Corken Coro-Vac CPS4V, Corken Coro-Vac CPS4X Important Instructions Manual

CPS1V

CPS4V

CPS6R

IMPORTANT
INSTRUCTIONS

OILL E S S SERI ES CORO -VAC
MODEL CYLINDER/TANK
PURGING SYSTE MS

IG100

This is the hazard alert symbol: When you see this symbol, be aware that personal injury or
property damage is possible. The hazard is explained in the text following the symbol. Read the
information carefully before proceeding.

The following is an explanation of the three different types of hazards:

DANGER Severe personal injury or death will occur if hazard is ignored.
WARNING Severe personal injury or death can occur it hazard is ignored.
CAUTION Minor injury or property damage can occur if hazard is ignored.

ASSEMBLY INSTRUCTIONS

1. Carefully remove the Corken Coro-Vac Cylinder Purge System from the shipping container
and inspect for any damaged components. Any loose or damaged components should be
reported to Corken, Inc. immediately.

2. Your Corken Coro-Vac Cylinder Purge System includes one vacuum pump. One inlet
hose assembly with fittings and vacuum gauge will be included loose with the vacuum
pump assembly.

3. Install inlet filter and muffler assemblies on CPS6R models only. Refer to exploded view.

4. Apply pipe thread sealant to the male pipe threads on the inlet hose assembly. Remove the
plastic plug over the inlet and install the inlet hose.

5. If necessary, install motor and coupling guard on CPS6R models only. Ensure that the unit
operates satisfactorily. If the unit does not operate properly, see the troubleshooting guide.

CYLINDER PURGING INSTRUCTIONS

This Corken Coro-Vac Cylinder Purge System may be used on multiple cylinders. The following
instructions apply regardless of the number of cylinders being purged. However, the inlet hose of
the Coro-Vac should be connected to a cylinder manifold instead of a single cylinder valve for
multiple cylinder purging.

1. Do not attach to any cylinder that contains LP Gas. This unit is to be used to purge air only.

2. Carefully read all instructions contained in this booklet before use. All warnings should be fully
understood before operation of this unit. Failure to comply with these warnings could result in
severe injury or death.

3. Vent any positive pressure through the cylinder outage or bleed valve before connection of
inlet hose. Retighten after pressure is vented.

4. Connect the inlet hose to the cylinder valve and tighten securely by hand.

5. Open the cylinder valve and switch on the Coro-Vac and allow the unit to pull 2 psia (see chart).

6. Close the cylinder valve and switch off the Coro-Vac.

7. Disconnect the inlet hose from the cylinder valve. The cylinder in now ready to be filled by
authorized personnel.

The following guide can be used to estimate required purge times for multiple cylinders:

*Purge times may vary depending upon cylinder valve manufacturer and

other restrictive fittings.

Number of Cylinders Coro-Vac Model Estimated Purge Time*

1-3 CPS1V/1X 2- 6 minutes

1-15 CPS4V/CPS4X 1 -15 minutes

500 Gallon Tank CPS6R 20 minutes

ATMOSPHERIC PRESSURE BY ALTITUDE
FOR CYLINDER PURGING

Altitude Above Atmospheric Barometer Gauge Reading Gauge Reading

Reference City Sea Level (ft) Pressure (psia) Reading (in. Hg) at 2 psia at 5 psia

Boston, PA 0 14.69 29.92 25.85 19.74

500 14.43 29.38 25.31 19.20
1000 14.17 28.86 24.78 18.68
1500 13.91 28.34 24.26 18.16
2000 13.66 27.82 23.75 17.64

Tucson, AZ 2500 13.41 27.32 23.24 17.13

3000 13.17 26.82 22.74 16.64
3500 12.92 26.32 22.25 16.14
4000 12.69 25.84 21.77 15.66
4500 12.45 25.36 21.29 15.18

Albuquerque, NM 5000 12.22 24.89 20.82 14.71

5500 11.99 24.43 20.35 14.25
6000 11.77 23.97 19.90 13.79
6500 11.55 23.52 19.45 13.34
7000 11.33 23.08 19.01 12.90

Mexico City, Mex 7500 11.12 22.65 18.57 12.46

8000 10.91 22.22 18.15 12.04
8500 10.70 21.80 17.73 11.62
9000 10.50 21.38 17.31 11.20
9500 10.30 20.98 16.91 10.80

Kenosha Pass, CO 10000 10.10 20.58 16.51 10.40

AIR CONTENT

Container Evacuated to 2 psia Conatiner Evacuated to 5 psia

Container Pressure Percentage Air Content Percentage Air Content

psig % %

0 13.3% 34.2%
25 4.9% 12.7%
50 3.0% 7.8%
60 2.6% 6.7%
75 2.2% 5.6%

100 1.7% 4.4%
125 1.4% 3.6%
150 1.2% 3.1%
175 1.0% 2.7%
200 0.9% 2.3%

The approximate container air content as a percentage of the total gas vapor mixture at standard
conditions using Dalton’s and Amagat’s Laws at two points with the empty container’s air volume
evacuated to 2 and 5 psia before being filled with propane vapor to gauge pressure is as follows:

*Dalton’s Law states that the total pressure of a mixture of gases is equal to the sum of the partial
pressures and each component of the mixture at its partial pressure occupies the total volume.

*Amagat’s Law states that if each component in a mixture of gases could be segregated at the
same temperature and pressure as the mixture, the sum of the separate volumes would equal
that of the original, and the partial pressure of each component would equal the total pressure.

GENERAL INFORMATION

This pump is only to be used for the purpose
of pumping air and under no circumstances
be used with any other gases. The pump
must not be used for the pumping of fluids,
particles, solids or any substance mixed
with air, particularly combustible substances
likely to cause explosions.

DANGER Do not pump flammable or

explosive gases, or operate
the unit in an atmosphere
containing them without
appropriate motor and
electrical connection.

CAUTION The exhaust air of this pump

can become very hot. Do
not direct exhaust air
towards property that is
temperature sensitive.

CAUTION This pump is designed for air

only. Do not allow corrosive
gases or particulate material
to enter the pump. Water
vapor, oil-based contaminants,
or other liquids must be
filtered out.

Ambient temperature should not exceed
40°C (104°F). For operation at higher
temperatures, consult the factory.

Performance is reduced by lower
atmospheric pressure found at high
altitudes. Consult a Corken distributor
for details (see chart).

Never lubricate this oil-less air pump.
The sealed bearings are grease packed,
and the service life of the rings or vanes
will be reduced by petroleum or
hydrocarbon products.

INSTALLATION

WARNING To avoid risk of

electrocution do not use
this product in an area
where it could come in
contact with water or other
liquids. If exposed to the
elements it must be
weather protected.

WARNING Beware of any exposed

moveable parts. Proper
guards should be in place
to prevent personal injury
or death.

CAUTION Do not block the flow of

cooling air over the pump in
any way.

CAUTION Do not lift the unit by the fan

shroud, filters or mufflers.

MOUNTING

This pump may be installed in any
orientation as long as the flow of cool,
ambient air over the pump is not blocked.
To reduce noise and vibration, mount to a
stable, rigid operating surface. If mounted
outside, cover or shield from the elements.

PLUMBING

To prevent air flow restriction, use pipe
and fittings that are the same size or
larger than the threaded ports of the
pump. The ports are marked "IN" and
"OUT”. Be sure to remove port plugs
before operating unit.

ACCESSORIES

Intake and exhaust filters are external to
the pump and will provide adequate
filtration for most applications. Check
filters periodically and replace when
necessary. Consult a Corken
representative for additional filter
recommendations. Install relief valves

and gauges at the inlet or outlet, or both,
to monitor performance. Check valves
may be required to prevent
backstreaming through the pump.

WIRING

WARNING Incorrect wiring can result in

electric shock. Wiring must
conform to all required safety
codes and be installed by a
qualified person. Grounding
is required. All power to the
motor must be de-energized
and disconnected when
servicing.

ELECTRIC MOTOR CONTROL

The motor must be protected against
short circuit, overload and excessive
temperature rise. Fuses, motor protective
switches and thermal protective switches
provide the necessary protection in these
circumstances. Fuses only serve as a
short circuit protection of the motor (wiring
fault). Fuses in the incoming line should be
chosen so as to be able to withstand the
starting current of the motor, not as a
protection against overload. Motor starters,
incorporating thermal magnetic overload,
or circuit breakers protect the motor from
overload or reduced voltage conditions.
Selection of the correct overload setting is
required to provide the best possible
protection. Refer to the motor starter
manufacturer's recommendations.

GROUNDING INSTRUCTIONS

Check with a qualified electrician or
serviceman if the grounding instructions are
not completely understood, or if in doubt as
to whether the product is properly grounded.

FOR ALL GROUNDED, CORD­CONNECTED PRODUCTS: This product

should be grounded. In the event of an
electrical short circuit, grounding reduces
the risk of electric shock by providing an
escape wire for the electric current. Some
units are equipped with a cord having a
grounding wire with an appropriate
grounding plug. The plug must be
plugged into an outlet that is property
installed and grounded in accordance
with all local codes and ordinances.

DANGER improper installation of the

grounding plug can result in
a risk of electric shock. If
repair or replacement of the
cord or plug is necessary do
not connect the grounding
wire to either flat blade
terminal. The wire with
insulation having an outer
surface that is green, with or
without yellow stripes, is the
grounding wire.

FOR A GROUNDED, CORD­CONNECTED PRODUCT RATED LESS
THAN 15 AMPERES AND INTENDED
FOR USE ON ANOMINAL 120v, or 220­240 VOLT SUPPLY CIRCUIT:

This product is for use on a nominal 120v
or 220-240 volt circuit, and has a
grounding plug, Make sure that the
product is connected to an outlet having
the same configuration as the plug, No
adapter should be used with the product.

FOR PERMANENTLY CONNECTED
PRODUCT:

This product should be connected to a
grounded, metallic, permanent wiring
system, or an equipment grounding
terminal or lead on the product (refer to
wiring diagram). Explosion proof versions
should be installed per code.

EXTENSION CORDS:

Use only a 3-wire extension cord that has
a 3-blade grounding plug, and a 3-slot
receptacle that will accept the plug on the
product, Make sure your extension cord
is in good condition. When using an
extension cord, be sure to use one heavy
enough to carry the current that your
product will draw. For lengths less than
50 feet, 16 AWG extension cords should
be used. An under-sized cord will cause a
drop in line voltage resulting in loss of
power and overheating.

ELECTRIC MOTOR CONNECTION

Refer to the motor nameplate for wiring
diagram. If the motor fails to start or
slows down under load, shut the pump off
and unplug it. Check that the supply
voltage agrees with the motor nameplate.
Be sure the 3-phase motor turns in the
proper direction of rotation after
installation. Turning in the wrong direction
will drastically reduce vane life, result in
overheating and cause unit damage.

OPERATION

Solid or liquid material exiting the unit can
cause eye or skin damage. Keep away
from air stream.

WARNING Some models are equipped

with glass jars. Proper
measures should be taken
to guard against the
fragmenting of breaking
glass if an alternate material
is not used. If hazard is
ignored, severe personal
injury of death can occur.

WARNING Always disconnect the

power before servicing.
The motor may be thermally
protected and will restart
automatically when it cools
if the thermal protection
switch is tripped.

WARNING Pump surfaces can become

very hot during operation.
Do not touch these surfaces
until unit has been shut off
and allowed to cool.

WARNING Do not operate without both

the coupling guard and
shroud in place. Failure to
do so could result in severe
personal injury.

CAUTION Do not operate units above

recommended pressures
or vacuum duties. To do so
will damage the unit.

Starting

If the pump is extremely cold, let it warm
up to room temperature before starting. If
the pump does not operate property, see
the Troubleshooting Guide.

WARNING Some models may exceed

85 dB(A). When in close
proximity to these models,
hearing protection is
required.

INSPECTION AND MAINTENANCE

Regular inspection can prevent
unnecessary damage and repairs. The
intake and exhaust filters require periodic
inspection and replacement. Initial
inspection is suggested at 500 hours,
then the user should determine the
frequency. Keeping filters clean can
prevent most problems. Dirty filters
decrease pump performance and can
diminish pump service life.

FILTER
INSPECTION / REPLACEMENT

The unit may become very hot during
operation. Do not touch until the pump
has been turned off and allowed to cool.

Refer to exploded view drawing during
the following procedure.

Make sure the pump is turned off, isolated
from the power supply , and that all pressure
and/or vacuum is released from the pump.

Remove filter cover and inspect felt. If
the felt is completely contaminated, it
must be replaced. Replace felt and
install cover.

Before putting the pump back into
service, ensure that any external
accessories such as relief valves and
gauges attached to the cover have not
been damaged.

SERVICE KIT INSTALLATION

NOTE: Corken will not guarantee the
performance of a field-rebuilt pump. You
can return the pump to a Corken
authorized service facility, or perform the
following rebuild procedures.

Kits contain most or all of the following.
Head gasket, Valves, Cylinder gasket,
Piston Ring, Piston Seal, Rider Ring,
Felts and Vanes. Kits are used for several
models and may contain extra parts not
applicable for your specific model. Refer
to exploded view.

Disconnect the pump from electrical power.

WARNING You must disconnect the

pump from electrical power
before you service it. Failure
to do so can result in severe
personal injury or death.

Pump Disassembly CPS1V, CPS1X,
CPS4V, CPS4X

Remove the shroud, cylinder head, and
valve components. DO NOT re-arrange
the valve components. Remove the
cylinder and rings. Make sure all parts
are clean before reassembling. DO NOT

use any chlorinated solvents to clean
valves, or any liquids to flush units, THE
STAINLESS STEEL VALVES MAY BE
CLEANED WITH WATER. All parts,
except the valves, can be cleaned with
any industrial, nonflammable, nontoxic,
non-petroleum based cleaning solvent.

Assembly:

• Install piston seals, piston rings, and
rider rings on the piston.

• Locate ring joints approximately opposite
each other.

• Attach cylinder to bracket with the
cylinder screws and washers.

• Tighten screws finger tight. Move
pistons to top dead center position.

• Adjust each cylinder flush with top of
piston and Torque cylinder screws to
150-160 inch lbs.. Retorque second time.

• Stack the valve components in order as
originally assembled.

• Install the cylinder head and head screws.

NOTE: The exhaust ports in the cylinder

heads have been marked by
omitting the ends of two of the fins.

• Do not tighten head screws at this time,
Install manifold nuts and seals on the
manifold and assemble into the other
cylinder head and manifold.

• Torque all head screws to 150-160
inch lbs.

• Turn fan by hand at this point to
ensure that the rod assembly is not
hitting the head.

NOTE: If rod assembly does hit head,

loosen cylinders and re-adjust.

• Position manifold and tighten Manifold
nut 1/2 to 3/4 turns beyond hand tight.

• Retorque head screws again after
running for 10 minutes.

CPS6R

3. Remove the shroud and fan.

4. Use a wheel puller to remove the

dead-end plate and bearing from the
pump body; note the direction of the
bevel edge on the vane. Do not
damage the dowel pins between the
end plate and the body. Save the
bearing spacer on the dead-end of
the shaft for reassembly. Remove
the snap ring from the end plate.
Save the snap ring, belleville
springs, and washer for reassembly.

5. Remove the bearing from the dead-

end plate.

6. Check the exposed surfaces of the

rotor, body, and end plate for scoring.

If you find no scoring, you can perform a
Minor Rebuild to replace only the vanes
and the deadend bearing.

If you find severe damage, perform the
Major Rebuild.

Minor Rebuild

7. Install the new vanes supplied with

the kit. Be careful to face the vane
bevels in the proper direction (as
noted in step 4).

8. Place end plate over the shaft with

dowel pins aligned. Place bearing
spacer on dead end of shaft. Place
the new bearing in its bore in the
dead end plate. Be careful to press
only on the inner bearing race.

9. Install and tighten the pump body
bolts. Install the belleville springs
with the washer between them, and
the snap ring.

Major Rebuild

7. Remove the drive end cap, Use a
wheel puller to remove the drive-end
plate and bearing from the body. Do
not remove or damage the dowel
pins in the body. Save the deflector
and endplate gasket for reassembly.

8. Place one of the new bearings in its
seat in the drive-end plate, then
place one of the shoulder rings on
the drive-end of the shaft. Using an
arbor press, press the bearing onto
the shaft. Be careful to press only on
the inner bearing race. Tighten the
pump body bolts.

9. Install the new vanes supplied with
the kit. Be careful to face the vane
bevels in the proper direction (as
noted in step 4).

10. Perform step #8 from Minor Rebuild.

11. Install the belleville springs with the
washer between them, and the snap
ring. Install and tighten the pump
body bolts.

12. Apply a thread-lock adhesive and
start the drive-end cap into its thread
in the drive-end plate, but do not
tighten it.

13. Place a dial indicator against the
dead-end of the shaft to measure axial
movement. Tighten the drive-end cap
until the indicator shows .002”.

14. Clean and reinstall filters.

Vacuum

Motor Excessive Won’t

Possible Reason Low High Overheating Overload Noise Start

Dirty Filter X at pump X X X
Dirty Muffler X X X
Plugged Vacuum Line X at pump X X
Vanes Sticking X X
Running at Too High RPM X X X X
Rings / Vanes Worn X X
Shaft Seal Worn (Replace) X
Particulate Material in Pump X X X X
Motor Not Wired Correctly X X X
Damaged / Dirty Valves X X
Improper Cylinder Alignment X X

TROUBLESHOOTING GUIDE

NO. DESCRIPTION QTY.

1 Muffler Assembly 1

• 2 Felt 1
3 Inline Filter (not shown) 1
4 Cylinder Head 1

• 5 Head Gasket 1

• 6 Valve, Outlet 1
7 Valve Plate 1

• 8 Valve, Inlet 1

• 9 Cylinder Gasket 1

10 Cylinder 1

• 11 Piston Ring 2

• 12 Piston Seal 2

• 13 Rider Ring 1
14 Piston Rod Assembly 1
15 Counter Weight 1
16 Flat Key 1
17 Fan 1
18 Shroud 1

• Denotes parts included in the Service Kit #5217.

CPS1V, CPS1X EXPLODED VIEW AND PARTS ORDERING INFORMATION

CPS4V AND CPS4X EXPLODED VIEW

AND PARTS ORDERING INFORMATION

NO. DESCRIPTION QTY.

1 Muffler Assembly 1

• 2 Felt 1
3 Inline Filter (not shown) 1
4 Cylinder Head 2

• 5 Head Gasket 2

• 6 Valve, Outlet 2
7 Valve Plate 2

• 8 Valve, Inlet 2

• 9 Cylinder Gasket 2

10 Cylinder 2

• 11 Piston Ring 4

• 12 Piston Seal 4
13 Piston Rod Assembly 2

• 14 Rider Ring 2
15 Flat Key 1
16 Fan 1
17 Shroud 1
18 Manifold Sleeve 2

• Denotes parts included in the Service Kit #5218.

NO. DESCRIPTION QTY.

1 Body 1
2 Rotor Assembly 1

• 3 Vane 4

• 4 Body Gasket 1
5 Foot Bracket 1

• 6 Deflector 2

• 7 Ball Bearing (Drive & Dead) 2
8 End Cap, Drive 1
9 Fan Coupling Assembly 1

10 Fan Guard 1
11 End Plate, Dead 1
12 Belleville Springs 2
13 Washer 1
14 Snap Ring 1
15 Fan 1

NO. DESCRIPTION QTY.

16 Fan Guard 1
17 Intake Filter Assembly 1
18 Gasket 2
19 Jar 2
20 Filter Assembly 1

• 21 Cartridge 2

• 22 Filter Felt 1
23 Muffler 1
24 Muffler Assembly 1
25 Fan 1
26 Flange 1
27 Sleeve 1
28 Flange 1
29 Retainer Ring 1

Service Kit 1

• Denotes parts in Service Kit.

CPS6R EXPLODED VIEW AND PARTS ORDERING INFORMATION

P.O. Box 12338, Oklahoma City, OK 73157

3805 N.W. 36th St., Oklahoma City, OK 73112

Phone [phone] • Fax [phone]

E-mail [e-mail]

Web address www.corken.com

Printed in U.S.A.

November 1999