Karcher IV100-55 User Manual
Industrial stationary
vacuuming systems
Planning Manual
English 5.906-587.0 Rev. 00 (05/14) 1
2 English 5.906-587.0 Rev. 00 (05/14)
Contents
1 Safety instructions 5
1.1 Hazard levels 5
2 When is a central vacuuming system used? 5
3 Target groups for a central vacuuming system 5
4 Advantages of a stationary vacuuming system 5
5 Abstract of the system planning 5
6 Components of a stationary vacuuming system 5
6.1 Suction unit 5
6.2 Collection and disposal container 5
6.3 Filter 5
6.4 Formed parts pipeline 5
6.5 Hose connections and switches 5
7 Prerequisite system planning 6
8 Basics of the system planning 6
8.1 Air speed 6
8.2 Route planning 8
8.3 System planning 8
9 Calculation tool 9
9.1 Calculation tool pipeline system 9
9.1.1 Modes of calculation 10
9.1.2 Conversion of units 13
9.1.3 Calculator 13
9.2 Calculation tool calculation of the pressure loss 14
10 Calculation of the pressure loss 15
10.1 Pressure loss calculation with the calculation tool 16
10.2 Addition of the sections 17
10.3 Alignment with vacuum cleaner characteristic 17
11 Sample calculation for the dimensioning of the vacuum cleaner 18
11.1 Step 1 18
11.2 Step 2 18
11.3 Step 3 18
11.4 Step 4 18
11.5 Step 5 19
11.6 Step 6 19
11.7 Step 7 20
11.8 Step 8 20
11.9 Step 9 20
12 Basics of the system installation 23
12.1 Overview module components 23
12.2 Examples for correct and incorrect system installation 24
12.3 Examples for the correct and incorrect branchings in the pipeline network 24
13 Use and setting of the false air valve 25
14 Installation instructions for tension ring connections with flanged sealing ring 26
15 Producing a flanged edge 28
15.1 Information concerning border sealings 28
16 General mounting instructions for the creation of tight connections 29
16.1 Installation instructions earthing bridge 29
17 Commissioning remote control 30
English 5.906-587.0 Rev. 00 (05/14) 3
17.1 Selecting the setup location 30
17.2 Installation 30
17.3 Functional description 30
17.4 Parameter IV vacuum cleaner control 30
18 Annex 1 - Questionnaire central vacuuming systems 5.906-589.0 31
18.1 Customer details 31
18.1.1 Preface 31
18.2 Checklist product 31
18.3 Checklist system 32
18.4 Other information 33
19 Annex 2 - Motor characteristics 34
20 Annex 3 - Pipe programme 35
4 English 5.906-587.0 Rev. 00 (05/14)
1 Safety instructions
5 Abstract of the system planning
1.1 Hazard levels
CAUTION
Possible hazardous situation that could lead to mild injury
to persons or damage to property.
Note
Indicates useful tips and important information.
2 When is a central vacuuming system
used?
– If the area to be vacuumed is locally fixed.
– If there is little space available at the working area.
– If the working areas are laid out over a large area and
several vacuuming points are therefore required.
– If the possible cleaning times must be limited due to the
production continuity
– If set-up and maintenance times are to be minimised.
– If the work environment must be kept hygienically
clean.
– If engine noises must be minimised in the working area.
– If large amounts of dust or fluid must be continuously
disposed of.
3 Target groups for a central
vacuuming system
Typical target groups for stationary vacuuming systems:
– Food industry
– Processing of metal and steel
– Processing of glass and stone
– Production of paper
– Production of starch and tobacco
– Textile industry
– Automobile industry
– Construction
– Transport
4 Advantages of a stationary
vacuuming system
– Immediately ready for operation, no set-up times.
– Space-saving, only the vacuuming accessories are at
the work station.
– Comfortable to use and safe to operate.
– Central suction unit and emptying at one point, thus,
space-saving and time-saving during maintenance.
– Long service life as parts transporting materials are
made of robust, sturdy material.
– Saving of costs thanks to the lower maintenance cost
of the entire system compared to several single systems.
– Saving of costs thanks to the acquisition costs com-
pared to single systems.
1 Description of the requirements and evaluation of the
situation of the customer.
2 Based on the known amount of material and material
characteristics to be vacuumed up, the number and
size of the vacuuming points and the resulting required
air speed is determined.
3 Planning of the routing.
4 Calculation of the pressure loss in the network with the
objective to optimise the line design
5 Matching with the vacuum cleaner types and detailed
planning of the routing.
6 Components of a stationary
vacuuming system
6.1 Suction unit
– All Kärcher industrial vacuums.
– Wet / dry vacuum cleaner and liquid aspirator.
– Explosion-proof vacuum cleaners are only certified for
the operation with defined hose lines.
The certification comprises a test of the total resistance
in the system (vacuum cleaner without accessories)
For a stationary system this can not be performed in ad-
vance.
If a customer requires an explosion-proof stationary
system, the installed system must be certified in a sin-
gle acceptance inspection by the named authority.
6.2 Collection and disposal container
– Container sizes and types as per the current main cat-
alogue.
– The pre-separator system (as per main catalogue) with
80 l container or for drums can also be used as a dis-
posal container (observe nominal diameter).
– Disposal bags in various designs as per main cata-
logue.
6.3 Filter
– All IV- and IVC vacuum cleaners have an integrated cy-
clone preseparator.
– Filter data of the main filters such as surface, material,
order number, etc. as per main catalogue.
6.4 Formed parts pipeline
– 4 Standard diameter:
DN 60, DN 80, DN 100 and DN 120
– Modular system with flanged pipes and tension ring
connections.
Thus, flexible replacement and extension.
– In galvanised steel or stainless steel (1.4301)
– System is suitable for dusts, chips and fluids.
6.5 Hose connections and switches
– Hose suspension with limit switch for the automatic
switch-on of the vacuum cleaner.
– Kärcher remote control for controlling the suction unit at
the vacuuming point.
English 5.906-587.0 Rev. 00 (05/14) 5
7 Prerequisite system planning
– Clarify with the customer in detail which requirements
the stationary system should fulfil.
The questionnaire for central vacuuming systems
5.906-589.0 helps, see Chapter "Annex 1 - Questionnaire central vacuuming systems 5.906-589.0“.
– The system design is based on the number of suction
stations to be operated in parallel and the amount of
material to be transported per vacuuming point.
8 Basics of the system planning
8.1 Air speed
Air is the transport medium for the vacuumed material. To
ensure that the vacuumed material is transported in the
entire pipeline network without depositing (material deposit) and clogging, a steady air speed must be present in the
network.
The required air speed varies for different vacuumed materials.
On its way through the line network the individual particle
of the vacuumed material does not fly straight from the
suction station to the disposal container. Thus, it always
requires more time from the vacuuming point to the disposal container than the air speed gives you reason to expect.
For this reason, an after-running time of the vacuum cleaner must always be provided for to prevent depositing due
to early switch-off.
Note
The perfect and thus targeted conveyance in the pipeline
is the flying transport.
Flying transport
Flow rate with an air speed of 20 m/s:
Suction hose Volume flow (flow rates/h)
DN 42 approx. 90 m³/h
DN 51/52 approx. 140 m³/h
DN 61 approx. 200 m³/h
DN 71/72 approx. 270 m³/h
Vacuumed material
Wood chips 50x20x1 mm 22-25 m/s
Sawdust (wood) Ø 0.7 mm 20-25 m/s
Steel balls Ø 1 mm 25-35 m/s
Active carbon Ø 3 mm 20-23 m/s
Plastic granules Ø 3.5 mm 20-23 m/s
Plastic powder Ø 0.2 mm 20-25 m/s
Area wood
Vacuumed material Air speed
Wood chips with pieces 25-30 m/s
Sawdust damp 22-24 m/s
Coarse wood chips without pieces 18-22 m/s
Wood wool 18-20 m/s
Small wood and planing pieces 16-18 m/s
Dimensions Air speed
Clogging transport
The smaller values can only be used with lines that are designed in a way that is favourable for the flow, e.g. with
short or vertical lines, elbows with a large radius, fork pieces with a small angle.
Finest wood dust 12-14 m/s
Area metal
Vacuumed material Air speed
Very coarse metal dust and
chips
Coarse metal dust and chips 20-22 m/s
Metal dust, chips 18-20 m/s
Fine metal dust 16-18 m/s
Metal smokes (welding) 14-16 m/s
Finest metal dust 12-14 m/s
Area food
Vacuumed material Air speed
Tobacco dusts 15-16 m/s
Grain and feeding stuff dusts 14-16 m/s
Flour 12-14 m/s
20-25 m/s
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Area paper, plastics
Vacuumed material Air speed
Scrap of paper 15-22 m/s
Rubber dust 18-20 m/s
Trimming suction 16-18 m/s
Swarf leather 15-16 m/s
Paint mist spray booth 14-16 m/s
Shorter textile fibres 12-16 m/s
Foamed polystyrene (expanded
polystyrene)
Area minerals
Vacuumed material Air speed
Coarse dry sand without gravel 18-20 m/s
Sandblasting, fettling shop 16-18 m/s
Swarf glass 16-18 m/s
Emery, corundum 116-18 m/s
Sand 14-16 m/s
Finest dry sanddust 12-14 m/s
Other
Vacuumed material Air speed
Detergent dusts 16-18 m/s
Oil mist suctioning 14-16 m/s
Coal dust pulverized 12-14 m/s
8-10 m/s
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8.2 Route planning
Note
The objective is to keep the resistance in the pipeline system as small as possible.
– Always choose the shortest possible way.
– Course as straight as possible with as few cracks and
bends as possible.
– Use of the ways of other supply runs e.g. of present
pipelines, cable runs etc.
– No obstruction of ways or systems.
– Provide for easily accessible cleaning opening.
– Optimum installation height is 2-3 m.
– Plan the junctions on the same height or with a slight in-
cline to the main line.
– Always align Y-pieces to the side, never towards the
top or bottom (medium can drain).
– The overall cross section of the nozzle at the machine
to be vacuumed off and its branch should not exceed
the cross sectional area of the suction stub at the vacuum cleaner.
– The suction stub at one single machine must not be
larger than the total connection cross section at the
vacuum cleaner.
– 90° junctions (tees) must be avoided in general.
– With longer branch lines the cross section of the pipe-
line should be chosen larger than the suction nozzle
connection.
– A taper of the pipe cross section must only be designed
smaller from the vacuum cleaner to the vacuuming
points and should be as close as possible to the vacuuming point.
– Every vacuuming point should be equipped with a lock-
ing slide that is always closed after the switch-off of the
machine or the end of the suction process.
– Hoses have a high pressure loss due to their large fric-
tional resistance. Due to this circumstance, the hose
lengths must be reduced to a minimum.
– Always use a hose sleeve at the end of the hose, and
earth the wire helix of the hose on the hose sleeve by
means of a screw in order to create a potential equali-
sation.
– All pipelines must be connected in an electrically con-
ductive way from the machine branch to the intercept-
ing pipe.
8.3 System planning
With the 4 given framework requirements a rough planning
of the stationary system can take place.
1 Spatial conditions.
2 Number of the overall and the simultaneously working
vacuuming points.
3 Required air speed.
4 Kärcher vacuum and pipeline programme.
Part one "Design pipe system" of the calculation tool for
stationary vacuuming systems can be used for the calculation of the pipe diameter (see Chapter "Calculation tool
pipe system design").
The inner diameter is calculated respectively and the pipe
closest to the calculated diameter is chosen.
With the fixed pipeline diameter the air speed actually
achieved must be calculated again.
If it does not suffice for the material to be vacuumed, the
pipeline must be redesigned or a more powerful vacuum
cleaner must be used.
8 English 5.906-587.0 Rev. 00 (05/14)
9 Calculation tool
The calculation tool can be called up online via the DISIS
and in SAP under the part number 5.906-608.0.
9.1 Calculation tool pipeline system
1 Auxiliary tool for the conversion of units and calculator
2 Selection "flow rate"
3 Selection "Air volume flow"
4 Selection "Inner pipe diameter"
5 Input fields
6 Button "Calculate"
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9.1.1 Modes of calculation
Calculation of the air speed
1 Selection "flow rate"
2 Input field "Air volume flow"
3 Input field "Inner pipe diameter"
4 Button "Calculate"
Fill in input fields with relevant values.
Press the "Calculate" button.
The value of the air speed is displayed.
10 English 5.906-587.0 Rev. 00 (05/14)
Calculation of the air volume flow
1 Selection "Air volume flow"
2 Input field "flow rate"
3 Input field "Inner pipe diameter"
4 Button "Calculate"
Fill in input fields with relevant values.
Press the "Calculate" button.
The value of the air volume flow is displayed.
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Calculation of the inner pipe diameter
1 Selection "Inner pipe diameter"
2 Input field "flow rate"
Depending on the material (see tabular values)
3 Input field "Air volume flow"
Depending on the suction performance from the technical data sheet of the selected vacuum cleaner
4 Button "Calculate"
Fill in input fields with relevant values.
Press the "Calculate" button.
The value of the inner pipe diameter is displayed.
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9.1.2 Conversion of units 9.1.3 Calculator
Overview
1 Input field convert value "from"
2 Display field convert value "into"
3 Selection of the units "from"
4 Selection of the units "into"
Convert units "from"
Auxiliary tool for the calculation of various values.
Overview of the units
Convert units "into"
Overview of the units
Select unit "from".
Select unit "into".
Enter the value into the input field, the conversion value
is automatically shown in the display field.
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9.2 Calculation tool calculation of the pressure loss
1 Loss coefficient or also pressure loss coefficient, pres-
sure loss coefficient, drag coefficient is denominated
with factor here.
2 The mass flow rate indicates the mass of a medium that
moves through a cross section within a period of time.
The mass flow rate is also referred to as flow rate. As a
standard, it can be calculated with 1.0 here.
3 Air is the carrier gas.
Under standard conditions (temperature 20 °C and air
pressure 1013 mbar) the density of air is ~1.2 kg/m³.
4 The kinematic viscosity describes the relationship be-
tween dynamic viscosity and consistency.
Under standard conditions it is always 0.000015 m³/s.
14 English 5.906-587.0 Rev. 00 (05/14)
10 Calculation of the pressure loss
In an ideal line network no losses would occur and the necessary suction unit could be determined with the two parameters air speed and volume flow. In the real line
network, however, losses are created due to resistances
and turbulences. These must be calculated as pressure
losses in the pipeline network in order to determine the required suction performance.
With branched pipelines only the way that causes the
greatest pressure loss (main run) must be determined. For
the calculation of the pressure loss the overall length is divided in sections with the same air quantity (volume flow)
and the same diameter.
A Section 20 m pipeline
B Section 5 m pipeline
C Section 10 m hose
In the individual sections the pressure loss is calculated individually and then added up to the overall pressure loss.
When calculating the overall pressure loss it must be observed which vacuuming points are operated simultaneously.
For the determination of the pressure differences per section the branch lines do not need to be calculated as they
are not relevant for the overall pressure loss of the system.
Branch lines must be closed if they are not in operation
(e.g. with sliders, caps, etc.) so that no false air (see Chapter "Use and setting of the false air valve") is sucked out.
Note
A security of 10 to 20% should be present as the volume
flows can not always be adjusted in the way they have
been calculated and to cover imponderables.
English 5.906-587.0 Rev. 00 (05/14) 15
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