Document: UVP IM 04-23-2012

Document: UVP IM 04-23-2012
Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
TABLE OF CONTENTS
INTRODUCTION .................................................................................................................. 3
WARNING .................................................................................................................... 3
OPERATING LIMITATIONS ..................................................................................... 3
UNPACKING .................................................................................................................... 4
GENERAL INSPECTION ..................................................................................................... 4
MECHANICAL INSTALLATION ...........................................................................................4
ELECTRICAL INSTALLATION ..............................................................................................4
UTILITIES .............................................................................................................................. 4
SPECIFICATIONS...................................................................................................................... 5
OPERATING AT HIGHER ALTITUDES .............................................................................. 5
PARTS LIST ........................................................................................................................... 8
MAINTENANCE AND INSPECTION..........................................................................................9
WARRANTY .............................................................................................................. 11
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© 2012 NOVATEC INC. All Rights Reserved
Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
INTRODUCTION
Novatec’s UVP series Vacuum Pump is designed to pneumatically convey plastic pellets or
powders in a vacuum conveying system. It does this by creating a vacuum to “pull” air through
the piping system. Plastic pellets or powders are introduced into the moving air stream in various
ways, including through the use of probes, pick-up tubes, and rotary air locks. The UVP is used in
conjunction with vacuum chamber station valves, etc. to form the conveying system, which is
controlled with either Master Control or Distributed Control Panels. Several vacuum power units
may be designed into the system as required. Vacuum conveying systems typically distribute
material from silos, surge bins, blenders, or drying hoppers to processing machinery.
WARNING
Always disconnect power before servicing. Only qualified technicians should service,
maintain, or repair the UVP. Before using this equipment, read in detail the product bulletins and
other information found in this manual. A safe installation is necessary before operating the
equipment. The instructions should be understood and followed before operating the
equipment. The instructions should be understood and followed before installing or using this
equipment.
To prevent damaging and potentially dangerous operation and performance limitations related to
the Elevation (altitude) of the pump-use site, see “Operating at Higher Altitudes” below, and
page 5 for instructions for user-required adjustments.
OPERATING LIMITATIONS
Operating At Higher Altitudes…3000 Ft Above Sea Level or More
Atmospheric pressure is lower at higher elevations and as a result, the compression of air by the
pump requires more work for vacuum conveying. In these higher altitude applications the pressure
relief valve of the UVP pump must be adjusted on site to prevent the pump from damaging itself or
the motor by attempting to compress air of reduced density to an unsafe level. See page 5 for relief
valve adjustment procedure instructions.
Exhaust Temperature
Blower exhaust temperature and motor cooling are a function of both vacuum level and elevation.
If operating the vacuum pump at elevations higher than 2500 feet above sea level, increased
exhaust and motor temperatures are likely and additional cooling provisions may be required to
guard against unsafe and damaging elevated temperatures.
Seek Time
Seek Time is a control parameter that allows your pump to operate for short period of time in
vacuum break mode while the system control searches for new demands. Excessive starting and
stopping will reduce blower and motor life and void the warranty. Pump starts must be limited to
12 per hour to prevent premature failure. The minimum Seek Time for a pump is 240 seconds to
prevent exceeding 12 starts per hour. Actual Seek Time required is dependent upon pump
capacity, utilization, number of stations, capacity of each vacuum chamber, and individual station
throughputs. (See your control panel instruction manual for information on Seek Time)
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© 2012 NOVATEC INC. All Rights Reserved
Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
UNPACKING
Caution should be exercised to see that the equipment is not handled roughly. The crate
must be removed carefully. The machine must not be used to pry against when removing
the crate. The vacuum power unit is usually shipped completely assembled and requires
no further attention prior to installation.
GENERAL INSPECTION
When the unit is unpacked, make a visual inspection looking for missing parts or damage
which may have occurred during shipment. All electrical and mechanical connections
should be checked for tightness, as vibration during transit may cause them to loosen. Oil
should be checked using the gauge located on the side of the UVP.
MECHANICAL INSTALLATION
Only qualified technicians familiar with local and national codes should install the
equipment. Connect the vacuum lines as shown on the installation drawings. Connect the
compressed air (80- 120 psig) to air actuated valves as required.
ELECTRICAL INSTALLATION
Connect the proper power supply (check nameplate) through a main line disconnect
(field supplied) to terminal connections L1, L2, L3 and ground into the UVP control
cabinet that contains the motor starter. This is the only power required, as the unit is
completely pre-wired. Connect additional control wiring from the remote mounted master
control panel to the vacuum power unit as shown on the electrical wiring schematic for
the master control panel. Verify the correct rotation of the motor with the directional
labels on the assembly.
UTILITIES
Compressed Air:
80-120 PSIG
Electric: Verify nameplate information
Horse Power
6.4HP
(UVP-6)
8.7HP
(UVP-9)
Voltage
460/60/3
400/50/3
460/60/3
400/50/3
4
© 2012 NOVATEC INC. All Rights Reserved
Full Load Amps
8.8
8.3
13.7
13.4
Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
© 2012 NOVATEC INC. All Rights Reserved
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Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
SPECIFICATIONS
Horse
Power
6.4HP
(UVP-6)
8.7HP
(UVP-9)
Operating Operating Vacuum Operating Operating Vacuum
Line Size
(60Hz, “Hg)
CFM (60Hz)
CFM (50Hz)
(50Hz, “Hg)
135
15-16
110
12-13
2.0”
200
15-16
165
12-13
2.5”
NOTE:
Refer to special job drawings for custom unit information if applicable. Verify nameplate
information on motor before installing and operating. All information is subject to change
without notice.
CAUTION:
Always disconnect power before servicing. Only qualified technicians should service the
equipment.
OPERATING AT HIGHER ALTITUDES (3000 Ft Above Sea Level Or More)
Atmospheric pressure is lower at higher elevations and as a result, the compression of air by the pump
requires more work for vacuum conveying. In these higher altitude applications the pressure relief valve of
the UVP pump must be adjusted to prevent the pump from damaging itself or the motor by attempting to
compress air of reduced density to an unsafe level.
The following chart shows the relief valve setting at different elevations for safe and effective pump
operation. If your pump-use location is more than 3000 ft. above sea level, the vacuum relief valve must be
carefully adjusted to the “Relief Setting” listed below using the procedure detailed on the next page in
“Adjusting The Vacuum Relief Valve Of The UVP Vacuum Pump”.
Site
Elevation
Sea Level
1000 ft. ASL
2000 ft. ASL
3000 ft. ASL
4000 ft. ASL
5000 ft. ASL
6000 ft. ASL
7000 ft. ASL
8000 ft. ASL
ASL = Above Sea Level.
Relief
Vacuum Guage
Vacuum Relief Valve
Setting
17.0” hg
17.0” hg
17.0” hg
16.0” hg
15.5” hg
15.0” hg
14.5” hg
14.0” hg
13.5” hg
“Hg = Inches of Mercury (as shown on the vacuum guage).
© 2012 NOVATEC INC. All Rights Reserved
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Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
ADJUSTING THE VACUUM RELIEF VALVE OF THE UVP VACUUM PUMP
Preparation
Prepare the following items and precautions for this adjustment:
Disconnect power to the vacuum pump and with the assistance of a qualified electrician, prepare a method of
operating the pump separate from the conveying system control. Operation must be triggered on and off
from the pump itself for your safety.
The pump must be operated separate from the vacuum system and with access to the vacuum inlet, so
disconnect vacuum hoses, manifold or tubing from the pump inlet port. The outlet of the pump (exhaust)
must be unrestricted.
Use extreme caution when working with the pump: In addition to heat, vacuum pumps create strong vacuum
suction during operation and the inlet to the pump must be kept completely clear of extraneous materials
including tools, documents, rags, shirts sleeves, etc.
Tools will be required for removal of the pump cover
and for the screws on the vacuum relief valve,
including: 2 mm, 4 mm and 5 mm right-angle Allen
wrenches plus a removable thread lock solution*.
A
A ”test plate” consisting of a smooth metal plate or
firm wooden board at least 4” wide and 12” long is
required for partially blocking off the vacuum inlet to
create resistance in the flow of vacuum air into the
pump. Assure that the selected item is clean and free of
paint or other coatings that may be sucked into the
pump during this high vacuum adjustment procedure.
B
A
Procedure:
1. Remove the main cover by first removing the lifting eye bolt, the four bolts surrounding the eye bolt
and the 6 bolts from the sides of the cover with a 4 mm Allen head wrench. The small top cover can
then be removed and the larger body may be carefully slid off the pump.
2. Locate the vacuum relief valve near the base of the inlet line (see picture).
3. Loosen the two set screws (A) within the larger slots on either side of the valve body with a 2 mm
Allen wrench, to allow adjustment of the relief valve.
4. Turn on the vacuum pump and allow it to operate with no obstructions on its inlet. Assure that the
vacuum pump can be easily shut off at any time during the procedure.
5. While observing the vacuum gauge, carefully place the test plate over approximately 50% of the
inlet tube, creating resistance on the flow of air into the pump. This is typically done by starting at
the edge and slowly moving/rocking the plate over the opening until the inlet approximately 50%
covered.
6. Observe the pump’s vacuum gauge and listen for the slip of the vacuum relief valve at the 50%
setting. If the relief valve is slipping open (allowing air to be sucked into the pump, to relieve its
pressure) yet the desired setting for your altitude has not been reached, move the plate to a lesscovered position over the inlet tube and repeat step 5. If the vacuum level has not yet been achieved
and the vacuum relief valve is not opening, proceed to the next step.
7. While slowly covering more of the vacuum inlet tube, observe the vacuum gauge and listen for the
opening of the vacuum relief valve. The goal is to establish the exact point at which the valve opens
and assure, by adjusting the valve, that it fully opens at the exact pressure required for your altitude
from the chart above.
© 2012 NOVATEC INC. All Rights Reserved
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Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
The vacuum relief valve is adjusted by turning
adjustment screw B with a 5 mm Allen wrench*
(as viewed from the screw side):
CW =
“hg
CCW =
“hg
Clockwise to reduce vacuum level.
Counter Clockwise to increase the vacuum level.
B
8. Perform several tests using this method; covering and uncovering the vacuum inlet and assuring that
the vacuum relief valve opens at the precise vacuum level listed above.
9. Once the desired set point is reached through adjustment of the vacuum relief valve, turn off the
pump, disconnect power and lock the setting by applying removable thread lock solution and
retightening the locking set screws (A).
10. Be sure to test the setting before placing the pump into service, using steps 5 through 8. Readjust as
needed.
11. Replace the covers and reconnect all tubing, fittings etc. to place the pump in service.
*In the rare event the adjustment screw (B) unscrews and begins to turn independent of the adjustment shaft,
making CCW valve adjustment impossible, perform the following steps:
1. Stop the adjustment procedure, turn off the pump and completely unscrew and remove the
adjustment screw from the adjustment shaft.
2. Carefully apply permanent thread lock to the adjustment screw threads.
3. Thread the screw back into the shaft and tighten snugly to assure it is bottomed down onto the
adjustment shaft. Retightening of the lock screws (A) may be required to assure a tight installation
of the adjustment screw into the adjustment shaft. Be sure to keep the thread lock solution off of the
adjustment shaft.
4. Allow the sealant to fully dry and/or cure according to its instructions before returning to your
vacuum relief adjustment process.
© 2012 NOVATEC INC. All Rights Reserved
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Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
UVP PARTS LIST
QTY DESCRIPTION
Part Number
6.4HP
8.7HP
4HP
1
15HP
UVP Pump
208V/230V/460V/
UVP-4-001 UVP-6-001 UVP-9-001
220V/400V/575V
1
Vacuum Relief
Valve
vrv20-18
1
Vacuum Gage
50011
UVP-15-001
Included with UVP (PN for maintenance)
UVP-SP-002
UVP-15-002
50011
50011
50011
1
Silencer (Muffler) UVP-4-002 UVP-6-002 UVP-9-004 UVP-15-002
Synchronizing
Included with UVP
INC
Gear Oil
(PN for maintenance: UVP-SP-001)
1
Solenoid VBV
115 VAC
08236
08236
08236
08236
24 VDC
08238
08238
08238
08238
1 Air Cylinder VBV
08945
08945
08945
10972
No
No
No
No
Disc
Disc
Disc
Disc
1 Motor Starter Box
Disc
Disc
Disc
Disc
230V (3/60)
eAN eBD eBN eDD eCN eDD eBN eCD
460V (3/60)
eAn eAD eAN eBD eBN eDD eAN eBD
575V (3/60)
eAN eAD eBN eBD eAN eCD eAN eAD
220V (3/50)
eAN eBD eBN eDD eCN eDD eBN eCD
400V (3/50)
eAN eAD eAN eBD eBN eDD eAN eBD
11966
11966
1
Filter Element
11966
11966
INC
Included with UVP
(PN: UVP-SP-003)
Inlet Screen
NOTE: Information shown is for standard vacuum power units. Refer to special job drawings for
custom unit information. Verify information on existing part before ordering and installing
replacement. All information is subject to change without notice.
© 2012 NOVATEC INC. All Rights Reserved
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Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
MAINTENANCE AND INSPECTION SCHEDULE
It is recommended that maintenance and inspection is done on a scheduled basis. Maintenance
requirements will naturally vary widely for each installation and specific operating conditions. It is
suggested that a complete inspection be performed with the necessary maintenance at the end of the
first day, the first week, the first month and the first 3 months. These inspections will be indicative
of how often future maintenance will be necessary.
EVERY WEEK
Inspect the Filter cartridge. Clean or replace as required. Remove any fines collected from the
catch pan. This time interval should be shortened if experience indicates unusual dust loading.
Check the system for air leaks and correct as required. If environment is dusty clean as described
under Every 6 Months
EVERY MONTH
Inspect the vacuum breaker valve filter/silencer. Clean or replace as required.
EVERY 3 MONTHS
Check level of the synchronizing gear oil, it should read lightly above the middle of the sight
glass. The level should stay consistent over the lifetime. If level falls the gear is leaking and the
vacuum pump requires repair.
EVERY 6 MONTHS
Check for loose electrical connections. Remove acoustic enclosure, ensuring foam mats do not
get soaked with water. Clean the fan cowlings, fan wheels, ventilation grilles and cooling fins.
Re-mount the acoustic enclosure. Tighten all bolts and nuts on the pump.
UVP15 Models Only: Models having grease fittings must be lubricated twice a year with the
high melting-point grease, Kluber Asonic HQ 72-102. For models without grease fittings,
grease only at overhaul. Grease can be added to the bearings by charging the bearings with
grease through the grease fitting until grease comes out of the opening.
EVERY 12 MONTHS
Clean (with compressed air) or replace the inlet filter. Check inlet screen below filter housing
inlet, clean if necessary. Change synchronizing gear oil according to vendor instructions on the
next page.
© 2012 NOVATEC INC. All Rights Reserved
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Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
Synchronizing Gear Oil:
Change oil once a year.
USE ONLY SPECIFIED OIL FROM PARTS LIST.
Remove eyebolt and lid. Depressurize the gear box by undoing the venting valve (UVP15:
remove oil fill plug on top of gear box). Drain oil and make sure seal ring on the drain plug is
serviceable, replace if needed. Reinstall seal and drain plug, insuring they are tightened
securely. Fully remove venting valve insuring the seal is undamaged. Fill new gear oil until the
level is slightly above the middle of the sight glass. Reinsert venting valve and seal.
Reassemble lid and eyebolt and dispose of used oil.
© 2012 NOVATEC INC. All Rights Reserved
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Document: UVP IM 04-23-2012
UVP Vacuum Pump Instruction Manual
WARRANTY – NOVATEC, INC. - Effective Date 9-28-2011
NOVATEC, INC. offers COMPREHENSIVE PRODUCT WARRANTIES on all of our plastics auxiliary
equipment. We warrant each NOVATEC manufactured product to be free from defects in materials and
workmanship, under normal use and service for the periods listed under “Warranty Periods”. The obligation
of Novatec, under this warranty, is limited to repairing or furnishing, without charge, a similar part to replace
any part which fails under normal use due to a material or workmanship defect, within its respective warranty
period. It is the purchaser’s responsibility to provide Novatec with immediate written notice of any such
suspected defect. Warranted replacement parts are billed and shipped freight pre-paid. The purchaser must
return the suspect defective part, freight prepaid and with identifying documentation to receive full credit for the
part returned. Novatec shall not be held liable for damages or delay caused by defects. No allowance will be
made for repairs or alterations without the written consent or approval of Novatec.
The provisions in equipment specifications are descriptive, unless expressly stated as warranties. The liability
of Novatec to the purchaser, except as to title, arising out of the supplying of the said equipment, or its use,
whether based upon warranty, contract or negligence, shall not in any case exceed the cost of correcting
defects in the equipment as herein provided. All such liability shall terminate upon the expiration of said
warranty periods. Novatec shall not in any event be held liable for any special, indirect or consequential
damages. Commodities not manufactured by Novatec are warranted and guaranteed to Novatec by the
original manufacturer and then only to the extent that Novatec is able to enforce such warranty or guaranty.
Novatec, Inc. has not authorized anyone to make any warranty or representation other than the warranty
contained here. Non-payment of invoice beyond 90 days will invalidate the warranty. A renewed warranty can
be purchased directly from Novatec.
Please note that we always strive to satisfy our customers in whatever manner is deemed most expedient to
overcome any issues in connection with our equipment.
Warranty Period:
Note: All warranty periods commence with the shipment of the equipment to the customer.
UVP Vacuum Pumps = 2 Years
Exclusions:
Routine maintenance/replacement parts are excluded from the warranty. These include, but are not limited to:
hoses, desiccant, filters, filter elements, wiper seals, gaskets, dew point sensors, infrared lamps, motors,
internal solenoids, fuses and motor brushes. Use with abrasive materials will void the warranty of any standard
product. Wear resistant options may be available to extend usable service life with abrasive materials.
Novatec reserves the right to limit the warranty if the customer installs replacement parts that do not meet the
specifications of the original parts supplied by Novatec.
*Specific Exclusions:
1. NovaDrier warranty is void if coalescing filters are not replaced on a 6-month or yearly basis (per instruction
manual) and/or membrane has been exposed to ozone.
2. NovaVac Dryer -The ability of the canisters to hold vacuum will be compromised if the vacuum seal edge is
damaged from mishandling. We do not warranty canisters damaged from improper handling. We do, however,
warranty the seals.
3. LOAD CELLS on our WSB’s are covered by Novatec standard warranty as long as they have not been
damaged from improper handling.
4. Velocity Control Valve warranty is voided if unit is placed in direct material flow.
This warranty shall not apply to equipment:
1. Repaired or altered without written approval of NOVATEC unless such repair or alteration was, in our
judgment, not responsible for the failure
2. Which has been subject to misuse, negligence, accident or incorrect wiring by others
3. Warranty is void if processing rates exceed manufacturer-recommended levels or if damage is caused by
ineffective power isolation and/or power spikes/sags or incorrect installation.
NOTE: All conditions and content of this warranty are subject to changes without notice.
© 2012 NOVATEC INC. All Rights Reserved
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Document: UVP IM 04-23-2012
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