Vacuum Pump PM60A

Rev. 00 of 1 September 2008 1 / 29 Series PM 60-70-80A USE AND MAINTENANCE MANUAL Email: sales@morousa.com www.morousa.com PITTSBURGH, PA OFFICE Sales Office (800) 383-6304 (412) 415-0421 Fax: (412) 415-3154 ST. LOUIS, MO OFFICE Po Box 632 Union, MO 63084 (866) 383-6304 Fax: (636) 583-2044 MORO USA, INC. Rev. 00 of 01.01.2009 2 / 29 PREMISE The vacuum pumps Farid - MORO S.p.A. division - are designed and manufactured in compliance with EC safety standards and subject to risk evaluation according to standard EN 1050; in particular they comply with directive 98/37/CE and later amendments and integrations. This manual includes the Declaration of the Manufacturer as per the above directive and all the indications necessary to the users and manufacturers of equipment to use our products in safety; thus the manual must always be kept near the vacuum pumps. It is necessary to read carefully the instructions included in this manual before proceeding with any operation with or on the vacuum pumps. This symbol of danger in the manual means that important safety instructions are given. These are directed to the operator, who is responsible for their respect by him and as well by other people exposed to the risks related to the use of the equipment. The descriptions and illustrations in this manual are solely indicative. The Manufacturer reserves the right to perform any type of change, at any time. WARRANTY When receiving the equipment, verify that all the parts of the vacuum pump are included. Any anomaly or missing part must be notified within 8 days from receipt. The Supplier guarantees that the goods sold are exempt from faults and defects and undertakes, only when such faults are clearly due to the manufacturing process or to the materials used, to repair or, based on its final assessment, to replace the defective parts. The Buyer shall be fully charged for labour, travel, transport, and duty expenses (if any). The Seller is not liable for damage compensation except in case of malice or negligence. The parts normally subject to wear are not covered by the warranty. Warranty is void in the following cases: ? The defects are due to accidents or evident negligence of the Buyer. ? The parts have been modified, repaired or fitted by people not authorized by the Seller. ? Failures and breakages have been caused by unsuitable uses or stresses exceeding those indicated in the maintenance booklet provided by the seller. ? The buyer has not complied with contractual payment obligations. The right to the warranty of the Buyer is void if the defects are not noticed to the Seller within 8 days form their discovery, in derogation to the clause 1512 of the Civil Code. The Seller reserves the right to change or improve its products without being obliged to change or improve the previously manufactured and/or delivered units. The Seller is not responsible for incidents or effects of the accidents on persons or goods due to defects of materials and/or manufacturing. Rev. 00 of 01.01.2009 3 / 29 MANDATORY SAFETY SIGNS THAT MUST BE POSITIONED ON THE WORKPLACE AND AROUND THE VACUUM PUMP Moving parts High temperature alert Crushing Mandatory personal safety devices Do not touch the drive shaft or any other moving parts when in use. Periodically lubricate the power takeoff. Read this manual before starting to use the vacuum pump Before start up verify the direction of the rotation of the switch lever to select vacuum (air flows away from the tank) or pressure (air flows towards the tank). Rev. 00 of 01.01.2009 4 / 29 USE CONDITIONS AND LIMITS - LIST OF DANGERS Installation must comply, for EC countries, with directive 98/37/CE and later amendments, while for the other countries it must comply with local safety standards. This vacuum pump is designed to create a vacuum or a pressure inside the connected tank. No liquid, dust and solid material must enter the vacuum pump because this may damage it. It is necessary therefore to provide the equipment with safety overfill valves. ? Any use of the vacuum pump different from that described in this manual, is to be considered as strictly forbidden, not foreseen by the Manufacturer and thus highly dangerous. ? Do not use the vacuum pump for flammable materials, explosives or materials that release flammable gas. ? Do not use the vacuum pump in potentially explosive atmospheres. ? Never remove the guards provided on the vacuum pump and check for their efficiency each time the machine is used. ? Any maintenance work must be performed with machine stopped. Non-compliance with the indications of this manual can result in the following dangers: ? Danger of crushing due to the weight of the vacuum pump during handling and transport. ? Danger of entanglement in the moving parts in case of removal of the guards. ? Thermal dangers due to high temperature reached by the vacuum pump. ? Acoustic danger due to the noise generated and to lack of use of personal hearing protection devices. ? Shearing danger for the operator during test with suction and/or discharge hoses detached from the pump. ? Danger of projection of solid and liquid materials due to severe breakage of the vacuum pump. Rev. 00 of 01.01.2009 5 / 29 TABLE OF CONTENTS PREMISE 2 WARRANTY 2 MANDATORY SAFETY SIGNS 3 USE CONDITIONS AND LIMITS - LIST OF DANGERS 4 TABLE OF CONTENTS 5 GENERAL INFORMATION 7 1 -VERSIONS OF THE VACUUM PUMP 7 USE AND MAINTENANCE INSTRUCTIONS 8 2 -PACKAGING, STORAGE, HANDLING AND TRANSPORT 8 2.1 PACKAGING 8 2.2 STORAGE 8 2.3 HANDLING AND TRANSPORT 8 3 -ASSEMBLY, INSTALLATION, DISASSEMBLY, REASSEMBLY 8 3.1 INSTALLATION LAYOUT 9 3.2 ASSEMBLY AND FITTING - INSTALLATION 9 3.3 REMOVAL 10 3.4 DISASSEMBLY 10 3.4.1 REAR SECTION DISASSEMBLY 10 3.4.2 FRONT SECTION DISASSEMBLY 11 3.5 REASSEMBLY - REINSTALLATION 11 3.5.1 REASSEMBLY OF THE REAR SECTION 11 3.5.2 REASSEMBLY OF THE FRONT SECTION 11 3.6 CORRECT POSITIONING OF THE DIVERTER VALVE 12 4 -HYDRAULIC LAYOUT (VERSION AH) 13 4.1 HYDRAULIC MOTOR USE AND MAINTENANCE INSTRUCTIONS 13 5 -COMMISSIONING - ADJUSTMENTS 14 5.1 OPERATION WITHOUT OVERPRESSURE/VACUUM VALVE FOR SERIES AIR 14 5.2 DIRECTION OF ROTATION 14 6 -OIL LUBRICATION AND CONTROL SYSTEM 14 6.1 FORCED LUBRICATION WITH GEARS 14 6.2 AUTOMATIC LUBRICATION 14 6.3 OILTO BE USED 15 6.4 OIL LEVEL 15 6.5 AMOUNT OF LUBRICATION OIL 15 6.6 LUBRICATION OIL REGULATION 16 Rev. 00 of 01.01.2009 6 / 29 7 –PRESSURE AND VACUUM RELIEF VALVES 16 8 -TEST AND RUN-IN 18 8.1 TEST 18 8.2 RUN-IN 18 9 -START-UP, OPERATION, STOP 19 9.1 START-UP 19 9.2 OPERATION 19 9.3 STOP 19 9.4 CONTROL DEVICES 19 9.5 PROTECTION DEVICES USED 20 9.6 PERSONAL PROTECTION DEVICES TO BE USED 20 10 -TROUBLESHOOTING 21 11 -MAINTENANCE, TESTS, REPAIRS, TECHNICAL SERVICE 22 11.1 CLEANING 22 11.1.1 WASHING OF BODY 22 11.1.2 WASHING OF OIL TANK 22 11.1.3 WASHING AND CLEANING OF VALVES 22 11.2 VALVES CHECK 22 11.3 INSPECTION AND REPLACEMENT OF THE VANES 22 11.3.1 FEATURES OF THE VANES 22 11.3.2 INSPECTION OF THE VANES 23 11.3.3 REPLACEMENT OF THE VANES 24 11.3.4 DIMENSIONS OF VANES (NEW) 24 11.4 REPLACEMENT OF THE RUBBER CHECK BALL 24 11.5 REPLACEMENT OF THE GEARS 24 11.6 TECHNICAL SERVICE 24 11.7 PERIODIC MAINTENANCE 24 12 -DECOMMISSIONING AND DEMOLITION 25 COMPANY CERTIFICATION IN COMPLIANCE WITH THE REQUIREMENTS OF THE STANDARD UNI EN ISO 9001:2000 26 DECLARATION OF THE MANUFACTURER 27 Rev. 00 of 01.01.2009 7 / 29 GENERAL INFORMATION 1. VERSIONS OF THE VACUUM PUMP The vacuum pumps of the AIR series can be delivered in the following versions: AIR SERIES AM AP AD AH P M 6 0 A O O O O P M 7 0 A O O O O P M 8 0 A O O O O Table 1 O = Available TECHNICAL SPECIFICATIONS Description Ref. PM 60A PM 70A PM 80A Free flow rate c.f.m. 252 322 417 Max. power required hp 15.6 17.8 20.2 Max. vacuum bar 95% 95% 95% Max. absolute pressure p.s.i. 29 29 29 Weight lbs 265 309 357 AM VERSION with overgear ? The pump shaft is a 1 3/8” spline and run at 540 rpm. This version can be recognized by the overgear box and by the identification plate located on the vacuum pump. AP VERSION with pulley application ? The pump is driven by a drive pulley (not provided) and an idle pulley (provided on request) and run at 1000 rpm. This version can be recognized by the identification plate located on the vacuum pump. AD VERSION with direct drive ? The pump shaft is 1 3/8” keyed and run at 1000 rpm. The version can be recognized by the identification plate located on the vacuum pump. AH VERSION with hydraulic drive ? The pump is driven by a hydraulic motor (provided on request) and it is recognizable by the support for hydraulic motor and by the identification plate located on the vacuum pump. Rev. 00 of 01.01.2009 8 / 29 USE AND MAINTENANCE INSTRUCTIONS 2. PACKAGING, STORAGE, HANDLING AND TRANSPORT 2.1 PACKAGING The AIR series vacuum pumps are provided without packaging. Packaging, such as wooden crates, can be requested for air or sea transport. 2.2 STORAGE For correct storage, the vacuum pump must be stored: ? indoor, protected from weather conditions; ? in horizontal position, resting on 4 feet. ? The vacuum pumps are lubricated, during test, at our plant, with a specific oil which ensures lubrication of inner components for approx. 6 months. In case of storage, we recommend to clean the inside of the pump with diesel fuel (or kerosene) and oil (as indicated in this manual). 2.3 HANDLING AND TRANSPORT Weight of the vacuum pump: (see annexed Technical Specifications). The vacuum pump must be: 1. Slung by metal hooks to be inserted into the eyebolt, or sling. 2. Lifted by forklift (if on pallet), bridge crane, crane. The vacuum pump is provided, as standard, with protection compliant with EC directives, which must be fitted by the installer using the screws provided. 3. ASSEMBLY, INSTALLATION, DISASSEMBLY, REASSEMBLY During maintenance, inspection, use and repair, we recommend the use of personal protection devices listed at the beginning of the manual. Rev. 00 of 01.01.2009 9 / 29 3.1 INSTALLATION LAYOUT Vacuum pump assembly layout (figure 1) Maintenance, inspection, use and repair must be performed with maximum care, with the drive switched off and the power take off disengaged. It is absolutely mandatory to avoid the ingestion of foreign bodies in the vacuum pump as this is likely to cause damage to the pump. It is thus necessary to provide the system with a primary trap “1” and a secondary trap “2” between the vacuum pump and the tank (see Figure 1). 3.2 ASSEMBLY AND FITTING - INSTALLATION The vacuum pump must be assembled and installed following this procedure: 1. Assemble the vacuum pump in horizontal position with its feet facing downward. The position of assembly on the vehicle must be easily accessible and protected. It is necessary not to exceed a longitudinal angle of 5° on the horizontal plane. 2. Position the vacuum pump and fasten it by means of bolts, nuts and washers in the specific slots or holes provided in the feet. 3. To install the vacuum pump: - version with overgear (…AM) it is necessary to connect the coupling of the 540 Rev. 00 of 01.01.2009 10 / 29 rpm PTO to the spline shaft of the vacuum pump. Do not exceed the maximum allowed angle of the PTO coupling - version with pulley (…AP) it is necessary to insert an idle pulley sheave on the drive shaft of the vacuum pump and fasten it by means of specific screw located in the front area of the shaft. The idle pulley can be directly mounted on the keyed shaft. Mount this sheave as near as possible to the bearing. Never transmit axial loads. Connect the two pulleys - the idle pulley to the drive pulley - by means of drive belts of suitable length. The number and type of belts used should be specified by the sheave manufacturer. At the end of this operation, it is necessary to install a belt guard (covering all belts and pulley sheaves) required to protect all operators. - - version with direct drive (…AD) it is necessary to connect the shaft of the PTO, gas/diesel drive or 1000 rpm electric motor to the drive shaft of the vacuum pump. Do not exceed the maximum allowed angle of the drive shaft. -hydraulic version (…AH) it is necessary to fit a hydraulic motor (SAE B 4 bolt for AIR series) and Moro hydraulic drive bracket and coupling to the pump. 4. Connect the rubber suction and discharge hoses from the tank to the vacuum pump fastening it to the hose barb fittings provided by means of a properly sized metal clamp. 3.3 REMOVAL The vacuum pump must be removed following this procedure: 1) stop the power takeoff. 2) remove the connections to the power takeoff and remove hydraulic connection (if any). 3) remove the hosing that connects the vacuum pump to the tank. 4) remove the mounting screws and remove the vacuum pump. 3.4 DISASSEMBLY 3.4.1 Disassembly of the driven side section ? Remove the driven side cover with the lubrication pump (together with the coupling) from the endplate. ? Remove the screws from the driven side endplate. Rev. 00 of 01.01.2009 11 / 29 ? Use two screws to be turned clockwise into the extraction threaded holes until the endplate can be removed. 3.4.2 Disassembly of the drive side section Overgear (…AM) Pulley (…AP) Direct (…AD) Hydraulic (…AH) 1) Remove the gearbox cover screws. 2) Use two screws to be turned clockwise in the extraction threaded holes until the cover can be removed. 3) Remove the gear with taper shaft using a puller if required. 4) Pinion: first unscrew the self-locking nut, then use a puller or press. 5) Remove the gearbox unscrewing the screws. 6) Remove the rotor from the body. 1) Remove the idle pulley and the key. 2) Remove the front cover from the endplate. 3) Remove the screws from the drive side endplate. 4) Remove the rotor from the body. 1) Remove the coupling with transmission flange and the key. 2) Remove the drive side cover from the endplate. 3) Remove the screws from the drive side endplate. 7) Remove the rotor from the body. 1) Remove the hydraulic motor from the support. 2) Remove the hydraulic motor support. 3) Remove the fastening screw inside the coupling and then remove it. 4) Remove the screws from the drive side endplate. 5) Remove the rotor from the body. 3.5 REASSEMBLY - REINSTALLATION IMPORTANT: Before any reassembly, replace all gaskets and oil seals. Replace vanes, bearings, check ball and any other wear parts as needed. 3.5.1 Reassembly of the driven side section ? Replace the gasket and the oil seals from the endplate cover. ? Bring the endplate near the pump body, positioning it in correspondence with the fastening holes. ? Insert the 6 fastening screws in the holes and tighten them. ? Make sure bearing is fully seated in endplate. Rev. 00 of 01.01.2009 12 / 29 ? Refit the rear cover with the lubrication pump (together with the coupling inside the rotor shaft) on the endplate. 3.5.2 Reassembly of the drive side section AM Version ? Replace all gaskets and oil seals. ? Fasten the gearbox endplate to the pump body by means of the specific screws. ? Make sure bearing is fully seated in endplate. ? Insert the key on the shaft and fit the pinion gear on the rotor shaft. ? Fasten the self-locking nut positioning the pinion gear. ? Install the gear with taper shaft. ? Position the gearbox cover gasket. ? Refit the gearbox cover using the previously removed screws. AP Version ? Replace all gaskets and oil seals. ? Fasten the drive side endplate to the pump body by means of the specific screws. ? Make sure bearing is fully seated in endplate. ? Refit the drive side cover with the specific screws. ? Insert the key on the rotor shaft. ? Refit idle pulley to rotor shaft. AD Version ? Replace all gaskets and oil seals. ? Fasten the drive side endplate to the pump body by means of the specific screws. ? Make sure bearing is fully seated in endplate. ? Refit the drive side cover with the specific screws. ? Insert the key on the rotor shaft. ? Refit coupling to rotor shaft. AH Version ? Replace all gaskets and oil seals. ? Fasten the drive side endplate to the pump body by means of the specific screws. ? Make sure bearing is fully seated in endplate. ? Insert the key on the rotor shaft. ? Fit the hydraulic motor support and coupling set. ? Refit the hydraulic motor with the specific screws. Rev. 00 of 01.01.2009 13 / 29 3.6 CORRECT POSITIONING OF THE DIVERTER VALVE For the correct positioning of the diverter valve follow this procedure: ? remove the valve handle. ? remove the valve cover. ? verify that the flat section of the diverter valve is at an angle of 45° in relation to the drive side shaft. ? refit (and replace gasket and seal) the valve cover and handle. 4. HYDRAULIC LAYOUT (VERSION AH) The layout of the hydraulic system required for the operation of the vacuum pump version …AH is indicated in Figure 2 and the technical features of the hydraulic motor in Table 2. The keying of the hydraulic motor is of type DIN 5482 - Z=23. Vacuum pump Hydraulic motor P/N Flow rate Pressure Transmitted power PM 60 /AH KM 40.73 28.27 gpm 2244 p.s.i. 28.16 hp PM 70 /AH KM 40.73 28.27 gpm 2457 p.s.i. 30.80 hp PM 80 /AH KM 40.109 36.19 gpm 2485 p.s.i. 40.22 hp Table 2 Rev. 00 of 01.01.2009 14 / 29 Figure 2 4.1) HYDRAULIC MOTOR USE AND MAINTENANCE INSTRUCTIONS In case of unidirectional motors, make sure that the motor is spinning in proper rotation. Make sure that the assembly flange is in good alignment between the pump shaft and the motor shaft. OIL TANK: The capacity of the tank must be suitable for the operating conditions of the system (about 3 times the circulating oil). To avoid overheating of the fluid, if necessary, install a heat exchanger. In the tank, the intake and discharge ports must be spaced by a vertical panel to prevent return oil from being immediately discharged again. HOSES: The nominal diameter of the hoses must not be smaller than the diameter of the motor inlets and the hoses must be perfectly sealed. We recommend use of a section of flexible hose to reduce the transmission of vibration. All return hoses must be below the minimum level of oil, to avoid allowing air into the circuit. FILTERS: We recommend filtering the entire system. HYDRAULIC FLUID: Use hydraulic fluids compliant with standards ISO/DIN. Avoid mixing different oils as this may cause oil decomposition, reducing its lubricating power. COMMISSIONING: Make sure that all the connections of the circuit are sealed and that the system is clean. Pour the oil in the tank using a filter. Purge the circuit to ease the filling of the system. Set the pressure regulating valves at the lowest possible value. Start the system for a few seconds at minimum speed, then purge the circuit again and check for the oil level in the tanks. If the difference of temperature between the motor and the fluid exceeds 50°F progressively heat the system. Gradually increase the pressure and the rotation speed until the required operating values are reached. PERIODIC CHECKS – MAINTENANCE: The external surface must be kept clean. Periodically replace the filter per manufacturer’s recommendations. According to the working conditions of the system, the oil level must be checked and it must be periodically replaced. 5. COMMISSIONING - ADJUSTMENTS 5.1 DO NOT OPERATE WITHOUT PRESSURE/VACUUM RELIEF VALVE Before starting the vacuum pump, make sure that the pressure and vacuum relief valves are properly mounted and set. Pressure relief valve should be set at 5 psi of less. Vacuum relief valve should be set at 18” Hg or less. 5.2 DIRECTION OF ROTATION Before starting the vacuum pump, make sure that the pump shaft rotates freely and that the direction of rotation is the same as that indicated by the arrow on the Rev. 00 of 01.01.2009 15 / 29 pump. Never operate the pump in the wrong rotation as the pump will not function properly and will likely result in damage. If rotation is incorrect for your system, contact an authorized service center. 6. OIL LUBRICATION AND CONTROL SYSTEM The vacuum pumps Farid Moro are designed with two different types of lubrication systems. (see Figure 3). 6.1 FORCED LUBRICATION WITH GEARS. The system is lubricated both in the vacuum and pressure functions by means of a gear pump in the rear area, driven by the rotor shaft. The gear pump pulls the oil from the tank and delivers it to the manually adjustable oil valve. Excess oil returns to the tank by means of a tube connected to the oil valve. Forced lubrication is available, as standard in Europe, on all models series AIR. 6.2 AUTOMATIC LUBRICATION. With this system, lubrication is performed in both vacuum and pressure functions by means of an adjustable flow rate dosing pump in the rear, driven by the rotor. The oil is directly injected in the pump housing, avoiding manual regulation and achieving a significant saving of oil. Automatic lubrication is standard on all U.S. AIR series pumps. 6.3 OIL TO BE USED. The vacuum pump is delivered without lubrication oil inside the oil tank and gearbox (if any). Pour mineral lubrication oil type ISO VG 100 (International symbol) in the oil tank and ISO VG 460 (International symbol) in the drive side gearbox (if used). Never use hydraulic or detergent oil. (Figure 3) Forced feed lubrication with gears Automatic lubrication 6.4 OIL LEVEL: For internal lubrication, the min. and max. level of oil are indicated by marks located on the stem of the dipstick (see Figure 4) located on the manifold. Rev. 00 of 01.01.2009 16 / 29 In the VERSION …AM the drive side gearbox is provided with an oil fill cap (1) in the top area of the gearbox and an oil level sight glass (2), in the side area of the gearbox, which allows you to check the level (see figure 5). For correct lubrication, the oil must always be visible in the sight glass. (Figure 4) (Figure 5) 6.5 AMOUNT OF LUBRICATION OIL: During vacuum pump operation, verify that the amount of oil indicated in Table 3 falls from the oil valve. When necessary, add new, clean, mineral oil to the tank. Version AM: Change the gearbox oil after approx. 100 hours of operation and then every 300 hours of operation thereafter. (Table 3) 6.6 LUBRICATION OIL REGULATION To regulate the amount of oil in the vacuum pump with gear lubrication (see Figure 6) is performed as follows: ? Loosen the lock ring “2” ? Operate the regulation ring “1” Rotating clockwise a reduced oil delivery is achieved (-), rotating counter-clockwise an increased oil delivery is achieved (+). When regulation is over, tighten again the ring “2” to lock pin “1”. Pump model Forced flow rate Automatic flow rate Oil tank capacity drops/min. fluid oz per hour quarts PM60 A… 20 - 25 5.41 1.80 PM70 A… 25 - 30 5.92 2.85 PM80 A… 30 - 35 6.43 3.91 Rev. 00 of 01.01.2009 17 / 29 The oil from the tank reaches tube “A”, enters the vacuum pump through the passage “B”; excess oil returns to the tank through tube “C”. Standard regulation of oil delivery, in automatic lubrication, is carried out at our plant during the final test of the vacuum pump. If, for any reason, a different flow rate is necessary (see Figure 7) proceed as follows: ? remove cover “3” ? loosen counternut “4” ? operate the register pin “5”. Rotating clockwise a reduced oil delivery is achieved (-); rotating anticlockwise an increased oil delivery is achieved (+). When the regulation is over, tighten the counternut “4” and tighten the cover “3”. (figure 6) (figure 7) 7. OVERPRESSURE AND VACUUM REGULATION VALVES The vacuum pumps AIR series do not come with pressure and vacuum relief valves. These accessories can be ordered separately, together with the aluminium hose connections or with the cast iron manifold. The threads on these accessories are Ø 2” NPT (pressure) and Ø 1 ½” NPT (vacuum). Vacuum: excessive vacuum can cause damage to the pump or vacuum tank. For this reason, we recommend to use a vacuum regulation valve “1” set to a max. value of 18” Hg. Pressure: max. possible pressure is 43 absolute p.s.i. (28 relative p.s.i.). We recommend using as little positive pressure as possible. A 2” pressure relief valve “2” should be used with a recommended setting of 5 PSI. To fit pressure/vacuum gauges, use the threaded hole “3”, on the two aluminium hose kits which can be provided on request. No. 2 valve support hose kits in aluminium Rev. 00 of 01.01.2009 18 / 29 Cast iron manifold valve support kit Vacuum and pressure relief valves should be set and locked as per manufacturer’s instructions. Make sure suction and discharge hoses are connected prior to testing any component of the vacuum system . In these conditions there is as well the risk to aspire foreign material from inside the machine. Current standards require that pressure relief valves be sized properly to insure all necessary air can be discharged to achieve necessary regulated pressure. Use table 4 below to determine the number of valves required to achieve proper regulation. Overpressure valves nominal flow rates according to I.S.P.E.S.L. E.1.D.2. Valve DN Inlet surface Square inch Reference pressure Prelative (Pr) / Pabsolute (Pa) PSI Flow rate Q CFM 1”1/4 1.24 sq. in 7.1 / 21.48 22.51 14.2 / 28.58 29.95 21.3 / 35.68 37.40 1”1/2 1.85 sq. in 7.1 / 21.48 27.34 14.2 / 28.58. 44.56 Rev. 00 of 01.01.2009 19 / 29 21.3 / 35.68. 55.62 2” 3.04 sq. in 7.1 / 21.48. 55.16 14.2 / 28.58 73.39 21.3 / 35.68 91.62 2”1/2 (free discharge) 4.37 sq. in 7.1 / 21.48 79.36 14.2 / 28.58 105.59 21.3 / 35.68 131.82 (Table 4) 8. TEST AND RUN-IN 8.1 TEST To test the vacuum pump, verify the items above, using if necessary a workbench. Make sure that the PTO shaft rotates freely and that the direction of rotation is the same as that indicated by the arrow. Verify that the position of the switch lever is correct and that the vacuum pump intakes and exhausts air freely. 8.2 RUN-IN The run-in period of the vacuum pump is about 50 hours of operation. 9. START-UP, OPERATION, STOP 9.1 START-UP The vacuum pump is not provided with a start switch. To start it, just transmit the drive to the shaft differently, according to the version of the vacuum pump. Make sure, prior to starting, that the pump has been filled with oil both in the oil tank for internal lubrication (all pumps) and in the drive side gearbox (version AM). Before starting the vacuum pump, make sure that the guards of all the moving parts are in place and in proper working order. Any damaged or missing part must be replaced and correctly installed before using the pump. 9.2 OPERATION Do not use the vacuum pump with pressure, temperature, speed and time values Rev. 00 of 01.01.2009 20 / 29 higher than those indicated in Table 5. Verify the following operating parameters. PARAMETER MAX OPERATING SPEED Speed …AM [rpm] 450 - 500 Speed, …AP, …AD, …AH [rpm] 1000 - 1100 Absolute pressure [p.s.i./rel] 0 – 28.4 Vacuum [%] 80 Max. external temperature of the vacuum pump [°F] 140 – 158 Max. continuous operating time [min] 18 - 20 (Table 5) Failure to comply with these parameters may result in damage to equipment and is a health hazard to the operator. If the density of the material to be pumped is high, dilute or mix the material before performing the operation. The operating time must be such to avoid the pump reaching maximum temperature. A long operation time without stops may cause, besides excessive heating, damage to vanes, housing and seals. 9.3 STOP To stop the vacuum pump, stop the motor and disengage the PTO so as to avoid involuntary operation. 9.4 CONTROL DEVICES A switch lever is provided as standard to control switching between vacuum and pressure modes. It is located in the top area of the manifold and can be used manually. To establish in which direction to turn the lever to select vacuum or pressure, comply with the labels provided by the truck manufacturer. NOTE TO MANUFACTURER: Either port can be as suction or discharge. Choose the ports that are most convenient and label them clearly. The selection of vacuum or pressure mode by the lever must be carried out with the vacuum pump stopped. Two accessories are available for remote control of the switch lever rotation; the first device is a Pneumatic (air) Actuator (figure 8), when connected to an air compressor, enables switch lever rotation. Rev. 00 of 01.01.2009 21 / 29 (Figure 8) The second device (figure 9), is a hydraulic actuator, when connected to a hydraulic circuit, enables switch lever rotation. Call your authorized dealer for further details and specifications on the pneumatic and hydraulic actuators. (Figure 9) 9.5 PROTECTION DEVICES USED The vacuum pump, when installed on a machine, must be provided with a protection device (guard) so that operators cannot access moving parts. It is necessary as well to cover the pump to avoid the danger of flying debris in case of severe failure. Versions …AM and …AD are provided as standard with a protection device in plastic material marked CE, to protect the PTO shaft during movement. In version …AH, no protection is required for power takeoff. 9.6 PERSONAL PROTECTION DEVICES TO BE USED During the use of the vacuum pump, it is necessary to use the personal protection devices required by the Manufacturer of the machine on which the vacuum pump is installed. Rev. 00 of 01.01.2009 22 / 29 10. TROUBLESHOOTING CHART ANOMALY DETECTED CAUSE SOLUTION Insufficient vacuum or pressure Vanes worn beyond recommended point Replace vanes Vanes partially stuck in rotor slots Disassemble the vacuum pump, clean and wash rotor, vanes, body. Air penetration or leakage from the system Remove penetrations Pump body phonographed/waved Hone or replace the body Switch lever not correctly positioned Remove and reposition correctly the switch lever Excessive heat Endplate to rotor clearance too tight (after repair) Add a gasket on the rear flange Excessive pressure Reduce pressure (adjust relief valve) Excessive speed Reduce the speed Excessive operation time Reduce operation time Lack of lubrication Verify oil level in the tank, oil pump operation, oiler adjustment, amount of oil used per hour Knocking sound during operation Insufficient speed Increase the speed to required RPM Excessive vacuum Reduce vacuum Sludge from the discharge port Malfunction of filtration system Check, and clean pump, primary, secondary and filter Smoke from the discharge port Excessive lubrication or wrong oil used Check lubrication and adjust if necessary. Check oil type/viscosity Lack of circulation of lubricating oil (versions with automatic lubrication) Aspiration of air from oil line connections Tighten or replace the connections Oil line not correctly inserted in the oil line connection(s) Loosen connection(s), fix oil line and tighten The oil pump chamber contains air Fill the oil pump chamber with oil The PTO does not rotate A vane has broken Replace the vanes (check all other internal parts) A foreign body has entered the vacuum pump Remove the foreign body (check all internal parts) No vacuum / no pressure The switch lever is not correctly positioned Position correctly the lever The vacuum pump is spinning opposite the required rotation Reverse the direction of rotation All the vanes are stuck in rotor slots Disassemble the vacuum pump, clean and wash rotor, vanes, body. Lubricate before starting The vanes exit the rotor slots unevenly Disassemble the vacuum pump, clean and wash rotor, vanes, body. Lubricate before starting Hose(s) between the pump and the tank are blocked or collapsed Remove blockage or replace hose(s) The primary and/or secondary ball(s) closing prematurely Call equipment manufacturer to correctly size the primary/secondary (Table 6) Rev. 00 of 01.01.2009 23 / 29 11. MAINTENANCE, TESTS, REPAIRS, TECHNICAL SERVICE During maintenance, inspection, repairs, we recommend use of the personal protection devices listed in this manual. Maintenance, inspection, repairs, must be performed with maximum care, with the vacuum pump switched off and the power take off disengaged. 11.1 CLEANING 11.3.1 Cleaning of the pump body. If any amount of sewage enters the vacuum pump, immediately clean the inside of the body by suctioning diesel fuel or oil, by means of the discharge hose with the pump in pressure mode. After this operation, inject fresh lubricating oil. The same operation is to be carried out when the vacuum pump does not operate for a long period of time. Prior to storage for an extended period, remove the suction and discharge hoses connected to the pump and cover any open ports. Wash the body with detergents (e.g. thinner). 11.3.2 Washing the oil tank. At least once a year, wash the oil tank with suitable detergents. 11.3.3 Washing and cleaning the oil valves (if applicable). At least once a month wash and clean the valves, if any, unscrewing them from the vacuum pump and cleaning them with water or non-corrosive detergents. 11.2 CHECK OF THE VALVES Periodically check that all valves (overfill, gate, check pressure/vacuum relief) are functioning properly. 11.3 INSPECTION AND REPLACEMENT OF THE VANES Pump vane features Two types of vanes made of different materials are fitted on the vacuum pumps, as indicated in table 7 (NOTE: All pumps sold in the USA use only the “heavy duty” vanes on all pumps): MODEL STANDARD HEAVY DUTY AIR 60 A O X AIR 70 A O X AIR 80 A O X (Table 7) O = STANDARD X = ON REQUEST (standard in USA) Rev. 00 of 01.01.2009 24 / 29 11.3.1 FEATURES OF THE VANES: STANDARD vanes are suitable for short, infrequent, light duty uses. The HEAVY DUTY (USA STANDARD) vanes are made of a special material suitable for vacuum pumps frequently used in industry. These vanes are highly resistant to wear and thermal/mechanic stresses. They are recommended for frequent uses and for the suction of thick sewage due to the longer time required to fill the tank. They are recommended as well for systems used frequently during the same day. Besides normal wear, vane replacement can be necessary due to a wrong use of the vacuum pump. The most frequent causes of defects are excessive heat, lack of lubrication, entry of sewage and/or fine dusts, high pressure or vacuum, creation of rust inside the body due to lack of use for extended periods. Excessive heat causes vane thickness to swell which prevents their free exit from the rotor slots; this issue is more frequent in standard vanes than in heavy duty vanes. If lubrication is insufficient, the vanes, as well as the inside of the pump, remain dry, they become brittle and breakage is likely. The same kind of breakage may be caused by the entry of sewage and/or fine dusts or by excessive operating pressure. Excessive vacuum causes the beating of the vanes against the cylinder which causes damage to the external face of the vanes. This also causes a “wave” in the housing cylinder. 11.3.2 INSPECTION OF THE VANES: To verify the wear of the vanes in the vacuum pump, proceed as follows: ? remove the threaded inspection cap (1), located on both the drive and driven sides. ? rotate the rotor to align a vane with the inspection hole. ? measure the distance (2) between the external surface of the rotor and the external face of the vane. ? if such distance is longer than 10-15% of the original height of the vane, replace the entire series of vanes. IMPORTANT: Before inserting the new blades, carefully check that the vane length matches that of the rotor slot. If not, contact an authorized dealer. Rev. 00 of 01.01.2009 25 / 29 REPLACEMENT OF THE VANES ? Verify if there is enough space to perform this operation with pump mounted, otherwise remove the pump from the support where it is fastened. ? Remove the pump endplate (whichever side is most convenient). ? Remove the vanes from the rotor. ? Clean the vacuum pump. ? Replace the vanes. ? Refit the endplate of the vacuum pump replacing all gaskets and seals. 11.3.4 DIMENSIONS OF VANES MODEL NUMBER OF BLADES DIMENSIONS OF BLADES (inch) AIR 60 A… 6 11.023 x 2.716 x 0.295 AIR 70 A… 6 14.173 x 2.716 x 0.295 AIR 80 A… 6 17.716 x 2.716 x 0.295 (Table 8) 11.4 REPLACEMENT OF THE RUBBER BALL ? Unscrew and lift the manifold. ? Replace the rubber ball. ? Close the manifold (replace all gaskets and seals). 11.5 REPLACEMENT OF THE GEARS (VERSION …AM ) ? Unscrew the screws of the gearbox cover. ? Remove the gearbox cover ? Remove the gear with taper shaft using a puller if required. ? Pinion: unscrew the self-locking nut, use a puller or press. ? Replace gears as necessary (replace all gaskets and seals). 11.6 TECHNICAL SERVICE For technical service and purchase of accessories and spare parts, contact the supplier of the equipment. Rev. 00 of 01.01.2009 26 / 29 11.7 PERIODIC MAINTENANCE MAINTENANCE TO BE CARRIED OUT MAINTENANCE METHOD FREQUENCY Oil circulation check Inspect the oil valve (if applicable) Once or more daily Tank oil level check Use the oil level dipstick located on the manifold Once or more daily Vanes wear check Per instructions in this manual Every 600 hours of operation or when any odd noise occurs Check correct operation of pressure and vacuum relief valves Per valve or equipment manufacturer’s instructions Once a week Washing of the oil tank Per instructions in this manual Once a year Washing the inside of the body Per instructions in this manual Once monthly (additionally each time sewage enters or when the equipment does not operate for a long period Washing the lubrication pump Use brush and compressed air Once a year or in case of long stop Check of correct operation of overfill traps Inspect and clean as necessary Once a month Lubrication of pump drive shaft (…AM and …AD) Oil the shaft with brush and lubricating oil Once a month Washing and cleaning of the oil valve Remove the valve Once a month (Table 9) 12. DECOMMISSIONING AND DEMOLITION Before the demolition of the vacuum pump, it is necessary to sort the following materials: ? lubrication oil from the tank, housing, manifold must be disposed of properly. ? parts in rubber and plastics; disposing of them properly. ? parts in cast iron and steel; disposing of them properly. Do not dispose of the vacuum pump in the environment. For the disposal of the lubrication oil, use specialized treatment services. Rev. 00 of 01.01.2009 27 / 29 COMPANY CERTIFICATION IN COMPLIANCE WITH THE REQUIREMENTS OF THE STANDARD UNI EN ISO 9001:2000 FARID MORO reserves the right to carry out any type of change, at any time, without notice. Data and measurements are indicative only. 0 01.01.2009 1st ISSUE R CQ R DT PRES Rev. Date Reason Prepared Approved Authorized Rev. 00 of 01.01.2009 28 / 29 DECLARATION OF THE MANUFACTURER FARID INDUSTRIE S.p.A. - Divisione MORO Via Pontebbana, 16 - 33080 FIUME VENETO (Pordenone) Tel. 0434 951211 – Fax 0434 959464 – VAT NO. IT06500530016 e-mail: pn-centralino@faridindustrie.it http://www.faridindustrie.it declares that its blade vacuum pump, for AGRICULTURAL applications COMPLIES WITH DIRECTIVE 98/37/CE AND LATER AMENDMENTS The main technical data are indicated in the plate which identifies the pump. It is forbidden to operate the machine in which the vacuum pump will be incorporated, before it is declared compliant with the provisions of the applicable directive. Fiume Veneto: 01 January 2009 Farid Industrie S.p.A. – div. Moro THE LEGAL REPRESENTATIVE Rev. 00 of 01.01.2009 29 / 29 __________________________