Vacuum Receivers VR and VRP Series

Vacuum Receivers VR and VRP Series
Vacuum Receivers
VR and VRP Series
Models: VR-5, VR-8, VR-12, VR-19, VR-38, VR-76, VR-114
VRP-12, VRP-19, VRP-38, VRP-76
VR Series
Pellet/Regrind
Receivers
VR-MM
Series
Receivers
©NOVATEC, Inc. 2012 All Rights Reserved
© NOVATEC, Inc. 2014 All Rights Reserved
VRP Series
Powder
Receivers
Document: VR-VRP IM 11-12-2012
Document: VR-VRP IM 11 NOV 2014
Instruction Manual VR-VRP IM 11 NOV 2014
NOTES:
Please record the following
information, which is specific to this
piece of equipment, in the space
provided. Our Parts/Service
Department will need these numbers
to properly respond to any of your
requests.
Instruction Manual: VR-VRP IM 11 NOV 2014
Model #:__________________________
Serial #___________________________
DISCLAIMER: NOVATEC, Inc. shall not be liable for
errors contained in this Instruction Manual nor for
misinterpretation of information contained herein.
NOVATEC shall not, in any event, be held liable for any
special, indirect or consequential damages in connection
with performance or use of this information.
FOREWORD
This manual is dedicated to the principle that any engineered system will have many elements
contributing to the smooth operation of the system, and that these must be understood in order that
installation and operation can proceed successfully.
The electrical and mechanical components in the GSL Series loaders have been manufactured,
selected and assembled with care to give you excellent service. All components of your GSL loader
have been carefully engineered and manufactured and have been thoroughly inspected for quality,
function and performance.
Before installing this system, please read this manual, review the diagrams and the safety
information. This should save valuable installation and operation time later and will help ensure safe
operation and long life.
© 2014 NOVATEC, Inc. All Rights Reserved
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Instruction Manual VR-VRP IM 11 NOV 2014
Table of Contents
1-UNPACKING AND INSPECTION ....................................................................................... 4
2-BASIC FUNCTIONS OF VACUUM RECEIVERS ............................................................... 4
2.1 NOVATEC VR SERIES RECEIVERS ........................................................................... 4
2.2 NOVATEC VRP SERIES RECEIVERS ........................................................................ 4
2.3 OPTIONS & ACCESSORIES ....................................................................................... 4
3.0 SPECIFICATIONS ........................................................................................................... 5
3.1 VR Series Vacuum Receivers....................................................................................... 5
3.2 VRP Series Vacuum Receivers .................................................................................... 6
4-PRINCIPLE OF OPERATION-VACUUM SYSTEMS .......................................................... 7
5-PRINCIPLE OF OPERATION-VACUUM RECEIVERS ....................................................... 8
6-RECEIVER INSTALLATION ............................................................................................... 9
6.1VACUUM BREAKER “T” VALVE INSTALLATION....................................................... 10
7-VRP SERIES RECEIVER COMPRESSED AIR INSTALLATION ..................................... 10
8-DEMAND LEVEL SWITCH WIRING ................................................................................. 11
9-INITIAL START UP ........................................................................................................... 12
9.1 VR (PELLET/REGRIND) RECEIVERS: ...................................................................... 12
9.2 VRP (POWDER) RECEIVERS: .................................................................................. 12
10-USE OF PROPORTIONING VALVES ............................................................................ 13
13-MAINTENANCE .............................................................................................................. 15
13.1 VR Series - FLAT SCREEN FILTER CLEANING: .................................................... 15
13.2 CARTRIDGE FILTER CLEANING ............................................................................ 16
13.3 WASHING CARTRIDGE FILTERS ........................................................................... 17
13.4 DRYING THE CARTRIDGE:..................................................................................... 17
14-TROUBLESHOOTING .................................................................................................... 18
14.1 PROBLEM: POOR OR NO CONVEYING: .............................................................. 18
15-WARRANTY – NOVATEC, INC. - Effective Date 6-12-2012 .......................................... 21
© 2014 NOVATEC, Inc. All Rights Reserved
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Document: IM VR-VRP 111 NOV 2014
Instruction Manual VR-VRP IM 11 NOV 2014
1-UNPACKING AND INSPECTION
After receipt of the unit, completely inspect it for damage. Although the units are packaged securely,
vibration and mishandling during transit can cause damage.
Since receivers are part of a system and do not operate alone, examine carton carefully for
accessories, wiring and spare parts that may have been included in the shipment. Check inside
chambers for parts and shipping materials.
2-BASIC FUNCTIONS OF VACUUM RECEIVERS
NOVATEC VR and VRP Series vacuum receivers are vessels for the receipt of materials conveyed
by a vacuum loading system consisting of a central vacuum pump, a control system and
interconnected vacuum tubing.
Each unit is designed to operate within a specifically pre-engineered central vacuum system and
must be matched to the line size of the system (tubing diameter), control voltage and throughput
capability. Each receiver must be accompanied by a range of accessories for its operation. These
components are purchased separately.
-control system
-vacuum breaker, or “T” valve
-tubing, bends, couplers and flex hose of the correct diameter for the vacuum system
-tubing, bends, couplers and flex hose of the correct diameter for material conveying
2.1 NOVATEC VR SERIES RECEIVERS
NOVATEC VR Series receivers are designed to receive virgin pellets and regrind materials vacuum
conveyed to them from storage containers and are typically located over drying hoppers, blenders
and process machines. VR series receivers are usually equipped with screen disc filters that permit
the passage of dust and fines, but hold the virgin/regrind in the receiver chamber.
Machine Mount versions are available for both the VR series to load material directly into the
machine throat.
2.2 NOVATEC VRP SERIES RECEIVERS
NOVATEC VRP Series receivers are designed to receive free flowing powders and are frequently
used on extrusion processes. VRP receivers are equipped with high capacity filter cartridges and a
blow down system designed to extend the operational life of the filter cartridges and keep all
conveyed material, dust and fines within the receiver chamber.
2.3 OPTIONS & ACCESSORIES
VR Options include:
 Alternate line sizes
 Alternate control voltages (in lieu of 24 VDC)
 DeviceNet Cables for 24 VDC
 High Heat Packages for materials above 225°F
 Alternate Glass Hopper Sizes ( for VR-MM models)
VR Accessories Include:
 Proportioning valves
 Capacitance Level Switch
 Pulsed Blowback Control
 Field Conversion Kits for Larger Glass Hoppers
VRP Options Include:
 Alternate line sizes
 Alternate control voltages (in lieu of 24 VDC)
VRP Accessories Include:
 Pulsed Blowback Control
© 2014 NOVATEC, Inc. All Rights Reserved
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3.0 SPECIFICATIONS
3.1 VR Series Vacuum Receivers
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Instruction Manual VR-VRP IM 11 NOV 2014
3.2 VRP Series Vacuum Receivers
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Instruction Manual VR-VRP IM 11 NOV 2014
4-PRINCIPLE OF OPERATION-VACUUM SYSTEMS
NOVATEC central vacuum conveying systems utilize a powerful vacuum pump to create vacuum
conveying power for a number of receivers. Receivers are interconnected with the vacuum pump
via tubing and a control system. Each receiver in the system has the ability to use the central pump
for vacuum conveying power within a sequencing arrangement...one receiver at a time. The
selected conveying control system in use determines the sequence of operation and triggers
vacuum isolation valves, known as vacuum breaker or “T” valves, located near each receiver, one at
a time, to allow vacuum to flow to each receiver with a demand for a set period of time. After that
receiver loads, the vacuum signal is passed onto another receiver with vacuum demand, allowing it
to load.
Vacuum systems typically employ a central dust collector, located near the vacuum pump. The dust
collector allows material fines and dust that are carried through from each receiver to be trapped,
before they are allowed to enter the pump. VR receivers are typically equipped with only screen
filters, freely allowing dust and fines to pass through and be trapped by the central dust collector. In
this regard, users find efficiency in two ways:
1. The conveyed materials are somewhat ‘stripped’ of dust and fines by the vacuum system. These
fines typically provide little value and/or actually detract from the molding process.
2. The maintenance required for the filter medium is greatly reduced and is more conveniently
located at floor level, near the pump.
VRP receivers are not equipped with flat screens, but very fine cartridge filters that trap all of the
material, dust and fines being conveyed.
Vacuum Header
Vacuum “T”
Valve
Vacuum
System
Control
VR or VRP
Receivers
Material
Loading
Dust Collector
Hopper
Mounting
with Flapper
Discharge
Machine
Mounting
with Sight
Glass
Vacuum Pump
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Instruction Manual VR-VRP IM 11 NOV 2014
5-PRINCIPLE OF OPERATION-VACUUM RECEIVERS
Each receiver is equipped with a material level switch that signals the control system with a
‘demand’ for vacuum power from the central pump to load. The switch may
be a tilt switch, located on the flapper valve below each receiver or in the
form of an electric eye that can sense the presence or absence of material in
a sight glass below the receiver. The switch is designed to signal a lack of
material and the need, or demand, for the material supply to be replenished.
Inlet check valve
inside receiver
The control system will receive the demand signal from the receiver and when it is able, send a
signal to that receiver station, allowing it to load. The receiver station is equipped with a vacuum
breaker that will open, allowing vacuum power to enter only that receiver, creating suction to pull its
discharge flapper valve shut and pull material to the receiver from the selected material source. As
material is pulled into the receiver vessel, it passes through a check valve on the receiver inlet and
the receiver’s chamber fills. The vacuum air used for this process is drawn through the filter media
of the receiver back towards the central pump for the time setting established on the central control
for that receiver. The filter media blocks the loaded material from entering the vacuum line that exits
the receiver.
Once the load time setting expires, the central control turns off its signal to that receiver, allowing the
vacuum breaker valve to close, shutting off the vacuum supply to that receiver. While the control
system directs the vacuum signal to move on to other receivers in the system, the loaded receiver,
no longer under the negative pressure of vacuum, gravity unloads its material into the vessel or
machine below it. At this point VRP receivers are triggered to blowback their cartridge filters with
compressed air, cleaning off collected dust and fines. The check valve installed on the material inlet
of the VRP, now closed, blocks the flow of the blow down air from entering the material conveying
line. VR receivers are not equipped with the blowback feature.
Material discharges from the chamber by gravity and flows to its destination
(dryer, blender, machine). If the loaded material completely evacuates the
chamber and does not back up into the receiver, the process will repeat.
This is the result of the discharge flapper on the base of the receiver, which
is pushed open by the discharged material, swinging back by gravity
towards closing after material is unloaded. The flapper’s demand switch
will indicate a new demand to the central control. If material does back up
into the receiver, it will not allow the discharge flapper to swing shut. This
will stop the demand switch on the flapper from sending another demand
signal to the control. Once material drifts away from the flapper, the flapper
will swing by gravity towards closing and once again create a demand
signal.
© 2014 NOVATEC, Inc. All Rights Reserved
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Counter-weighted flapper
discharge valve with tilt
demand switch.
Document: IM VR-VRP 111 NOV 2014
Instruction Manual VR-VRP IM 11 NOV 2014
Machine mounted units do not require a flapper valve or demand tilt
switch, but instead utilize a clear sight tube, which mounts vacuum-tight to
the machine throat, with a sensor to control loader operation based upon
the level of material within the sight tube. In many cases, a redundant,
vacuum-sealing flapper is added to the sight glass, to assure a vacuum
tight seal for loading. The sensor used on machine mount sight glasses
may be a capacitance type, with a sensitivity adjustment, set against the
glass, or a pair of photoelectric sensing elements called an emitter and a
receiver that send a signal through the glass. In either case, the function
is similar to the flapper tilt switch in the way it signals the central control
system when material is not present and that the receiver requires loading.
Note that a sensor on the sight glass may be vertically adjustable for
different levels of material in the sight glass, IE: The user can adjust at
what level the receiver will call for more material.
VR-MM Machine Mount with
photo-eye demand switch.
6-RECEIVER INSTALLATION
Mount the receiver body to the hopper lid, positioning it so that the material inlet is directed towards
the material pick up point or conveying line. Make sure the dump valve flapper has enough room to
move freely. Secure the receiver to the hopper lid with captive bolts or clamps to ensure a safe
installation with no chance of hardware vibrating loose. Ensure a tight seal when securing the loader
to the hopper or machine. This is particularly important for VRP units that will be conveying powder.
On machine mounted units, the bottom flange is usually supplied undrilled to allow a range of
mounting patterns and hardware choices. A gasket is used to provide a tight seal between the
receiver base and the machine throat.
Conveying lines should be installed horizontal and/or vertical, using a 90 degree radius bend for
directional changes, and it should be as direct as possible with no slope. All connections must be
vacuum tight. Rigid conveying tubing should be properly supported by the installer to provide a safe
and secure installation. Use flexible material handling hose to connect the material pick-up lance or
vacuum take-off box to the conveying line. The flexible hose should be only as long as needed,
since excess hose will reduce loader efficiency and is prone to rapid wear.
© 2014 NOVATEC, Inc. All Rights Reserved
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Document: IM VR-VRP 111 NOV 2014
Instruction Manual VR-VRP IM 11 NOV 2014
6.1VACUUM BREAKER “T” VALVE INSTALLATION
Each receiver in the vacuum loading
system requires a vacuum breaker valve
to be connected to it, which in turn is
connected to the central vacuum header
Pneumatic Solenoid:
coming from the vacuum pump/dust
• Connect to control
collector. The header typically
• Connect to
interconnects several receivers with the
compressed air
vacuum pump. See separate instructions
for vacuum breaker valve installation.
Vacuum Header
Vacuum Header
The vacuum breaker valve is the key
device for directing vacuum power to the
Vacuum
receiver for operation. On VR series
receivers, the vacuum breaker valve is
Breaker
the only electrical/pneumatic device
“T” Valve
associated with the receiver, unless other
options are employed. The valve requires
a connection to clean and dry
To lid of
compressed air, between 80 and 125 psi.
Receiver
The valve also requires electrical
connection to the control system being
used. See the central control instructions to assure that the solenoid on the vacuum breaker valve is
the proper voltage and for connecting the valve solenoid coil to the control system.
Connect the vacuum breaker valve to the lid of the receiver as described in the vacuum breaker
valve instructions. Depending upon the installation, the valve to receiver connection can be a
combination of tubing and flex hose as required, but should be kept as short as possible. The final
connection to the lid of the receiver should be provided with flex hose to allow easy removal of the
receiver lid for cleaning and maintenance.
7-VRP SERIES RECEIVER COMPRESSED AIR INSTALLATION
VRP series receivers include an on-board compressed air filter blowback system consisting of an
accumulator, solenoids, and cartridge filters inside the receiver. Connect a clean, dry compressed
air supply line to the accumulator tank. The minimum
requirement for effective filter cleaning is 80 PSI. Do not
exceed 125 psi. A flexible connection is often desired for
this connection since movement of the accumulator
section is often required for effective cleaning and
maintenance of the receiver. Utilizing a non-restricting
quick disconnect will allow full removal of the receiver if
necessary.
Compressed Air
Connection
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Document: IM VR-VRP 111 NOV 2014
Instruction Manual VR-VRP IM 11 NOV 2014
8-DEMAND LEVEL SWITCH WIRING
Each receiver is equipped with a demand level switch that must be connected to the central control
system. The switch may be in the form of a tilt switch on the discharge flapper valve, a capacitance
sensor or rotating level switch, located in a bin below the receiver, a photoelectric switch on the sight
glass of a machine throat receiver, or some other form. In all cases, this demand switch is required
to tell the central control system when this receiver is in need of material. Since the receiver may be
moved occasionally for cleaning or equipment changes, NOVATEC provides most demand switches
with twist-lock connectors, allowing the receiver to be removed while the wiring to the control to can
remain intact. This robust connector provides a reliable connection point for wiring to the control.
The following illustrations show 24 VDC wiring details for common NOVATEC demand devices. Use
these illustrations in conjunction with the wiring instructions for your central controls to carefully
connect the demand switches to your control system.
Green LED is ON when
power is connected.
Amber LED is ON when
switch is conducting.
Green LED is ON when
power is connected.
Receiver
Emitter
Brown (V+)
Blue (V-)
Black (NO)
White (NC)
Brown (V+)
Blue (V-)
DC application only.
Insulate to prevent
short circuit
S
C
Reed or
DistanceSensitivity
Adjustment
S
S
C
G
G
S=Silver Screw
G=Green Screw
C= Copper Screw
Rear View of Male Plug
Rear View of Male Plug
Male
Male
Female
Plug Set
provided
Female
INSTALLATION
WIRING
C
V+ (24 VDC)
C
G
Male
Plug Set
provided
Plug Set
provided
V+ (24 VDC)
C
S
S
Rear View of Female Plug
V- ( 0 VDC)
G
Level Switch Demand (24 VDC)
Typical Photo-eye
Demand Switch
S=Silver Screw
G=Green Screw
C= Copper Screw
S=Silver Screw
G=Green Screw
C= Copper Screw
Rear View of Male Plug
Female
INSTALLATION
WIRING
INSTALLATION
WIRING
Rear View of Female Plug
S=Silver Screw
G=Green Screw
C= Copper Screw
Gray (x2)
White (demand)
Blue (0 volts)
Brown (V+)
Indicator Light:
ON for demand
(no material in
front of sensor)
S=Silver Screw
G=Green Screw
C= Copper Screw
Mercury
Mercury
Switch
Switch
Demand Flapper mounted Tilt Switch
Capacitance
Level Switch
Output:
Clockwise = NC
CounterClockwise = NO
0 Volts
G
Rear View of
Female Plug
S
G
S=Silver Screw
G=Green Screw
C= Copper Screw
Level Switch Demand
Demand Input
Typical Capacitance
Demand Switch
+24 VDC
C
Typical Discharge Flapper
Tilt Demand Switch
CAUTION: Follow All Plant Wiring Formats
and Local or National Electrical Codes.
© 2014 NOVATEC, Inc. All Rights Reserved
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Document: IM VR-VRP 111 NOV 2014
Instruction Manual VR-VRP IM 11 NOV 2014
9-INITIAL START UP
9.1 VR (PELLET/REGRIND) RECEIVERS:
For optimum receiver operation, adjust the vacuum-on load time on the central control so that the
vacuum chamber is almost completely full at the end of the load cycle. Do not allow the chamber
to overfill.
Adjust the dump time so that it is only 1 to 2 seconds longer than the time necessary to completely
empty the chamber.
9.2 VRP (POWDER) RECEIVERS:
For optimum receiver operation, adjust the vacuum-on load time at the central control so that the
lower vacuum chamber is almost completely full at the end of the load cycle. VRP series powder
receivers include an extended body to house the cartridge filters. Loaded material should not be
allowed to be filled up into this extended hopper area. It is intended only as a housing for the filter
cartridges, not a high capacity hopper for collecting loaded material. Do not allow the chamber to
overfill.
Adjust the dump time so that it is only 1 to 2 seconds longer than the time necessary to completely
empty the chamber. Coordinate dump time with the blowback cycle (see below) to assure that the
bulk of loaded material has evacuated the chamber efficiently, while filters are being cleaned.
The number of blowback pulses needed to clean the filter cartridges depends upon the material
being conveyed. Free-flowing, unblended powder will require minimal filter cleaning while heavily
loaded, blended powders may necessitate the maximum filter cleaning sequence to keep the
cartridges free of accumulation and allow longer operational life between manual cleanings and/or
replacement. Refer to the instructions accompanying the specific filter-cleaning blowback control
being employed for adjustment instructions. Adjust the pulse cycle so the filters remain clean. A
mid-range setting is suggested as a starting point.
Note that during discharge and blowback, the check valve inside the VRP receiver should swing shut
by gravity, preventing blowback air from flowing down through the conveying line and possibly
ejecting dust into the atmosphere at the feed tube or take off box. If dusting is experienced out of
the material conveying line, decrease the load time to prevent the check valve from becoming
jammed with loaded material, which can prevent it from closing, when vacuum is removed.
© 2014 NOVATEC, Inc. All Rights Reserved
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10-USE OF PROPORTIONING VALVES
Proportioning valves are a convenient method for introducing regrind into the process while vacuum
loading of virgin material. The proportioning valve is typically installed onto the material inlet of the
receiver and is connected to the central control system, or an accessory control specifically designed
for proportioning valve operation.
Note that a proportioning valve should never be relied upon for accurate mixing of two materials, but
are only a process convenience for loading a second material (typically regrind). An ideal use of a
proportioning valve is emptying a granulator of reground material, in quantities known to not exceed
the limitations or specifications of the process. If requirements for the proportioning valve require
more accuracy, consult with NOVATEC regarding the use of a blender in lieu of a simple
proportioning valve.
External
Proportioning Valve
Solenoid: Connection to
control and connection
to compressed air
supply.
Material #1
inlet,
typically
Virgin
Material #2
inlet,
typically
Regrind
Material Outlet,
connected to
receiver Inlet
Proportioning valves and their associated controls split the central control’s vacuum-on time
for a particular receiver into two parts: one for loading virgin and one for loading regrind.
Making initial settings for the proportioning valve will require:
1. Determining and setting the approximate percentage of vacuum on time to be
dedicated to regrind loading, based upon the specs of the product being produced.
2. Depending upon the control being used, determining and setting the approximate
percentage of vacuum on time to be dedicated to virgin loading.
3. The number of valve switches (virgin/regrind/virgin/regrind, etc.) the valve will perform
while vacuum loading, to encourage “mixing” of the two materials.
4. Increasing the vacuum-on time to compensate for use of the proportioning valve.
© 2014 NOVATEC, Inc. All Rights Reserved
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Be aware that use of a proportioning valve will ask the vacuum system to alternately vacuum convey
two materials, and each time a material is to be loaded, it takes time to stimulate the material into
motion by vacuum. This process adds valuable time to the conveying process and can create
conveying problems if too many ‘mixing’ cycles are set on the control.
Also, the density and flow characteristics of virgin and regrind materials are typically very different,
as well as the conveying distances. These factors must be taken into consideration as the
percentage and number of valve cycles are set on the proportioning controls. A 50% setting of
vacuum time dedicated to regrind will never equate to a 50% quantity of regrind material ending up
in the receiver. It is best to make trial and error tests of proportional loads to see what results are
created rather that assuming a specific outcome based purely on control settings.
It is common that vacuum on time for any receiver equipped with a proportional valve must be
increased to allow for the dual loading capabilities of the proportioning valve.
© 2014 NOVATEC, Inc. All Rights Reserved
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13-MAINTENANCE
13.1 VR Series - FLAT SCREEN FILTER CLEANING:
VR Series receivers are typically used for conveying virgin pellets and/or regrind. The amount of
regrind or small, irregularly sized particles within the conveyed materials that might be trapped in the
screen, along with conveying velocity and throughput will all determine the frequency of necessary
screen filter cleaning. Typically a standard screen filter will only need to be manually cleaned when
changing materials. Or in the event of infrequent (or no) material changes, once a week.
CAUTION: Be sure to turn off the receiver at the central control
and/or disconnect electrical power and compressed air supplies
before any type of maintenance. Receivers may be
automatically energized to operate with no warning, startling the
maintenance worker.
The filter screen may be removed for inspection and cleaning by
unclamping the ring clamp of the lid, directly below the vacuum
connection. If necessary, disconnect the vacuum line. Carefully
remove the lid and expose the flat disc filter directly below the lid. The screen may now be removed
for inspection and cleaning.
Vacuum cleaning the bottom of the screen is recommended to removed collected resin debris, dust
and fines. If compressed air is used, be sure to wear goggles and blow from the top (course,
expanded metal side) of the filter down through the finer screen media. Never bang the filter against
a hard surface to dis-lodge debris. Distortion of the media or sealing ring can result.
Once clean, thoroughly inspect the filter for severe wear, holes, tears and material abrasion. Any
break in the filter media indicates the need for new filter. Do not attempt to repair the screen.
Remember that the screen assures that loaded material makes it way into the process and not to the
vacuum line, central dust collector or pump. In addition, examine the sealing ring around the screen
filter. This ring provides the vacuum seal between the lid, the filter and the receiver body. The ring
must be smooth, clean and intact to provide a suitable seal for vacuum sealing. Replace the filter if
the seal is not in perfect shape.
Once cleaning/inspection is complete, the filter may be reinstalled by placing it on the flat rim of the
loader body (fine screen DOWN and course screen UP) and placing the receiver lid down upon it
and centering the screen filter between the two. Replace the clamp and tighten. With newly
installed filters, the clamp may need to be adjusted to provide a vacuum-tight and mechanically firm
seal.
© 2014 NOVATEC, Inc. All Rights Reserved
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13.2 CARTRIDGE FILTER CLEANING
VRP Series receivers are typically used for conveying free flowing powder materials. For this task,
they are equipped with higher capacity cartridge filters. The amount of dust within the conveyed
materials will determine the frequency of necessary manual filter cleaning.
NOTE: Although the blowback system of the receiver will extend the operational life of the filter
media, it cannot be relied upon alone. Frequent checks of the filter accompanied by thorough
manual cleanings are required, in addition to cleanings during material changes to prevent cross
contamination.
CAUTION: Be sure to turn off the receiver at the central control and/or disconnect electrical power
and compressed air supplies before any type of maintenance. Receivers may be automatically
energized to operate with no warning, startling the maintenance worker.
The cartridge filters may be removed for inspection and
cleaning by unclamping the ring clamp of the lid, directly below
the vacuum connection. If necessary, disconnect the vacuum
line. Carefully remove the lid and expose the cartridge filter
mounting plate directly below the lid. The cartridge filter
mounting plate, with the cartridge filters installed below it may
now be carefully removed for inspection and cleaning.
If compressed air
is used, blow down
through inside of to
outside.
Vacuum Cleaning
If only light cleaning of the cartridge filters is required, the
of filter(s) exterior
filters may remain installed onto the filter plate and cleaned
is recommended
in place. However, full removal and thorough cleaning of
each cartridge is highly recommended. Vacuum clean the outside of the filters to
remove collected resin debris, dust and fines. If compressed air is used, be sure
to wear goggles and blow from the inside of each filter down through and out of
the filter media. Never bang a filter against a hard surface to dis-lodge debris.
Distortion of the media or sealing ring(s) can result.
VLP Cartridge
Filter
Once clean, thoroughly inspect the filter for severe wear, holes, tears and material abrasion. Any
break in the filter media indicates the need for new filter cartridge. Do not attempt to repair the
media. Remember that these filters assure that loaded material makes it way into the process and
not into the vacuum line, central dust collector or pump. In addition, examine the sealing ring around
the top of each filter cartridge. This seal provides the vacuum seal between the cartridge filter and
the filter mounting plate and must be fully intact. Replace the cartridge if this seal is not perfect.
© 2014 NOVATEC, Inc. All Rights Reserved
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13.3 WASHING CARTRIDGE FILTERS
Polyester filter cartridges, supplied as standard with all NOVATEC VRP receivers are also
washable to extend their life. Use one of the procedures outlined below. This cleaning
procedure enables soiled filter cartridges to be put back into operation at lower pressure
differentials. Cartridges may be washed several times to extend their operational life, but
use caution to avoid letting high pressure water puncture filter media that may already be
weakened by prolonged exposure to abrasive materials during vacuum loading:
POLYESTER FILTER CARTRIDGES WASHING, VARIANT A:
Wash with a commercial high-pressure cleaner, in compliance with the following conditions:
 Pressure: Temperature: max. 212°F (100°C)
 Cleaning agent: Maximum pH 5 - 7
 Cleaning Procedure: 8 to 10 pleats can be cleaned at a time, moving slowly from top
to bottom, holding the nozzle approximately 12 in. (30cm) away from the filter. Water
collecting inside the filter at the bottom can be drained out by tilting the cartridge.
POLYESTER FILTER CARTRIDGES WASHING, VARIANT B:
 Wash with a jet attachment from a conventional water hose.
 Cleaning procedure: Hold the hose at a distance of at least 2 inches (5 cm) from the
surface of the cartridge, and use the jet to spray out each pleat from top to bottom.
13.4 DRYING THE CARTRIDGE:
The cartridge must be thoroughly dried in order to ensure trouble free operation after they
have been cleaned. Choose:
 Dry at room temperature for a period of not less than 1 week.
 Dry in an oven at temperatures of max. 212°F (100°C) over a period of 12 hours.
Once each cartridge is cleaned, dried and inspected, it may be re-installed onto the filter
mounting plate in the same fashion it was removed. Examine the filter mounting plate to be
sure it is intact and its perimeter seal is smooth and clean since it will
form a vacuum tight seal between the receiver lid, the filter mounting
plate and the receiver body. Replace the seal if it is not in perfect
shape.
Once filter cartridges are mounted to the filter mounting plate, reinstall
it by placing it on the flat rim of the receiver body with the cartridges
down inside the body. At this point, it is critical that each cartridge
filter is located directly below one of the receiver lid’s blowback
nozzles that will clean it during the blowback sequence.
3 Cartridge Filters are
By viewing the receiver lid and the blowback nozzles on the
Mounted on a Common
Plate in all Models
underside of it, the filter plate may be rotated into proper position
Except the VRP-5
prior to placing the lid down on it and centering the filter plate
between the two. Each blow down jet on the lid must be centered over a cartridge filter for
effective blowback action. Replace the clamp and tighten. With newly installed filter plate
seals, the clamp may need to be adjusted to provide a vacuum-tight and mechanically firm
seal.
© 2014 NOVATEC, Inc. All Rights Reserved
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Instruction Manual VR-VRP IM 11 NOV 2014
14-TROUBLESHOOTING
14.1 PROBLEM: POOR OR NO CONVEYING:
1. VACUUM T VALVE OPERATION
Each vacuum receiver in the conveying system is coupled to a vacuum “T” valve that
isolates the vacuum conveying power of the pump to one receiver at a time for conveying.
Each T valve in the system must close off air flow when it is NOT in operation, allowing
other receivers to receive full vacuum. One ‘stuck’ valve can ruin the vacuum supply for the
entire system. Check that each valve operates in response to its receiver’s turn in the
vacuum system. Each valve should open for loading and close when loading is complete.
The extended shaft of the valve’s cylinder is a good indication of valve operation.
Rule of thumb: If only one receiver in the system is conveying correctly, it is probably that
receiver’s T valve that is not closing properly.
2. RECEIVER DISCHARGE FLAPPER STUCK OPEN
The flapper valve at the base of the receiver provides three critical functions:
 Seal off the base of the receiver, creating a sealed vacuum chamber and allowing it
to load,
 Open reliably to allow material to empty out and
 Signal the conveying control system of the need for more material (when it swings
shut, by its own weight).
If the flapper valve is stuck open or does not fully close, conveying cannot take place. A
problem receiver can be easily checked for proper, free movement of its flapper valve:
 If conveying is not triggered when the flapped is closed, there is an issue with the
electrical demand switch.
 If the flapper does not swing nearly shut by its own weight, there is a pivot point
(hinge) or counterweight issue.
 If the flapper is ‘stuck’ in the open position, there is a material contamination issue
with the pivot point (hinge) of the valve and it must be cleaned and examined for
wear. Contamination of the hinge is typically caused by material, finding its way into
the pivot point, but in older receivers, may also be a metal burr that has formed from
age.
3. INLET CHECK VALVE STUCK OPEN
Many receivers are equipped with swinging check valves on their material inlets. Check
valves provide a variety of useful functions for system operation and are pushed open when
material is conveyed into the receiver. But on systems that convey material from one source
to multiple receivers, each check valve in the system must seal to allow the one receiver
being loaded to receive the full vacuum force from the conveying pump. A check valve that
is stuck open, either by hinge wear or a trapped pellet, will leak valuable vacuum air,
decreasing vacuum capability at other receivers or even preventing conveying throughout
the system.
Rule of thumb: On systems that convey material from one source to multiple receivers via a
common material line; If only one receiver in the system conveys correctly, it is probably that
receiver’s check valve that is not closing properly.
© 2014 NOVATEC, Inc. All Rights Reserved
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Instruction Manual VR-VRP IM 11 NOV 2014
4. CONVEYING CONTROLS NOT PROPERLY (RE) PROGRAMMED
Central material conveying systems that include a network of pumps, receivers and material
sources provide high efficiency and a multitude of flexibility. But often, new requirements
are not completely programmed after material or system configuration changes. Items to
check:
 Is the new material source further away than the previous source? More conveying
time and/or purge time might be required to accommodate this difference in distance.
 Is the new material as free-flowing as the last material? Does the material have a
tendency to clog the conveying lines, or simply convey slower due to weight or
shape? Changes to load/purge times as well as material pick-up tube changes may
be required.
 Has the receiver been assigned to the proper vacuum pump? The proper material
valve?
 Has system piping and or wiring been modified to accommodate this new
configuration for conveying?
5. CONFIRM PROPER VACUUM BREAKER VALVE OPERATION
Located on the central vacuum pump of the system, the vacuum breaker valve allows
ambient air to be drawn into the pump when the conveying system is NOT conveying. This
function prevents rapid re-starts and stops of the pump during the “seek” time of the loading
control, cools the pump and prevents the over loads in the pump starter from over heating.
But the pneumatically-operated breaker valve must close and seal when the vacuum system
is conveying material, directing all vacuum force to the job of conveying. Check the
following:
 The valve is connected to a reliable source of clean compressed air, which is turned
on. Air pressure should be 85-120 psi.
 The valve must not be leaking vacuum air. Often a sucking sound can be heard,
indicating the valve is not sealing properly.
 View the level of vacuum created by the pump on its vacuum gage while attempting
to convey material: Although the reading on this gauge will vary greatly depending
upon your system configuration, it is a valuable tool for assessing system operation
and discovering faults. Vacuum levels below 6” indicate a breaker valve fault or other
problems in the vacuum system.
© 2014 NOVATEC, Inc. All Rights Reserved
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Document: IM VR-VRP 111 NOV 2014
Instruction Manual VR-VRP IM 11 NOV 2014
6. CHECK THE SOURCE OF YOUR MATERIAL
Easily overlooked, the source of your material may be either empty or the wrong tubing or
valve connections have been made.
Common bulk box issues are:
 Rat-holing: The feed tube has sucked up all the free-flowing material around its pickup end and the material must now be stirred to allow material to flow into the feed
tube again. A Gaylord tilter may be helpful in this situation.
 Bag liner line plugging: The feed tube has sucked in the thin film lining of the gaylord,
blocking off material flow to the receiver.
 Feed tube fell out of the box: By weight of its own hose, or by vibration of the flex
hose while conveying.
 Out of material: Time to move in a new bulk box.
Common material selection issues:
 Conveying line connected to the wrong source of material:
 Wrong purge valve selected: If a purge valve is used at the material source, it must
be programmed by the system control to operate in conjunction with a specific
receiver. Material changes require making a new valve selection at the system
control.
 Purge valve is not operating: If a purge valve is used at the material source, it must
be energized to allow material loading (and de-energized for purging). A fault at this
valve, IE: lost compressed air connection, an open purge valve access door or a
material jammed purge valve will prevent material movement.
7. FEED TUBE / TAKE-AWAY BOX AIR SETTINGS
The conveying of material by air cannot be accomplished without air movement.
Regardless of the type of pickup device being used; purge valve, wand, take-off box, etc.…
these devices must be adjusted to allow the introduction of material and air, in a mixture
suitable for conveying the specific material the distance required.
© 2014 NOVATEC, Inc. All Rights Reserved
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Instruction Manual VR-VRP IM 11 NOV 2014
15-WARRANTY – NOVATEC, INC. - Effective Date 6-12-2012
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.
VR & VRP Series Loaders = 1 Year
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.Touch screen controls on NovaWheel dryers have a 2-year warranty. All other controls have a 1-year warranty
3. 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.
4. LOAD CELLS on our WSB’s are covered by NOVATEC standard warranty as long as they have not been
damaged from improper handling.
5. 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.
© 2014 NOVATEC, Inc. All Rights Reserved
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Document: IM VR-VRP 111 NOV 2014
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