Web Operation Manual August 2019 - RVS Pumps

InstallationOperation Manual

Models- M- M- M9000 - M10000 - M12000D I VT

Serial Number

Site Location

Installation Date

Models- M- M- M3000 - M4000 - M7000D I VT

Experts in Vacuum Generation & Vacuum Control

RVS VacPumps Pty LtdSalisbury SA 5108Tel: +61 (0) 88285 5800 [email protected]

Rev. May 2019

1

Please read this manual

most out of your pump.It will help you to get the

Still have questions?

very carefully

Call the RVS Team61(0)882855800

Email:[email protected]

Copyright: The content of this publication can not be

from RVS Pumps Pty.Ltd.copied in part or whole without the written permission

READ THESE INSTRUCTIONS VERY

CAREFULLY BEFORE INSTALLING

YOUR NEW RVS PUMP, EVEN IF YOU

REPLACE AN EXISTING PUMP Failure to do so may result in problems and severe

damage to your new vacuum pump.

As RVS Vacuum Pumps are used in many different applications, it is difficult to cover each of them in a manual such as this. However, regardless of the

operation or application the pump is being used on there are some strict rules and guidelines that apply

to all of them.

MOST IMPORTANT POINTS TO NOTE!

RVS Vacuum Pumps are designed to pump only air and therefore should be protected from the intrusion

of all foreign material and liquid in any form.

MANDATORY PUMP PROTECTION Please read all instructions very carefully making sure

that your main tank has been fitted with all mandatory safety equipment especially when replacing your old

pump with a new unit. See Page 10

Your RVS Pump is a precision built unit and must betreated in accordance with the instructions supplied Failure to fit the mandatory safety equipment and work

outside specified speed limits can ruin your pump.


Rev3 May 2019

2

Cleaning up the Exhaust Some applications require an oil catcher/muffler to clean the exhaust air of all oil before discharging it into the atmosphere. lf this applies to your installation ensure that the oil catcher/muffler is drained regularly. RVS can

Setting up the Oil Reservoir

To achieve reliable lubrication the oil reservoir lid should be about 100 mm to 110mm higher than the Visifeed glass Mount the reservoir in a convenient place away from the heat of the pump. See picture below. Warning: Don’t mount the reservoir to high because oil syphoning might occur which could fill the pump with oil and cause pump damage on startup.

Visifeed Part Below all parts of the Visifeed are shown.

1 2 3 4 5 6 7 8 9 10 11

Part# 1 Airfilter Part# 2 Adjusting Valve Part# 3 Dripping Hook Part# 4 Sight glass O ring Part# 5 Infeed Banjo Part# 6 Sight glass with O ring Part# 7 Visifeed Head Part# 8 Head fastening Bolt Part# 9 Visifeed Stem Part#10 Stem Olive Part#11 Stem Compression Nut

1 2 3 4 5 6 7 8 9

Part# 1 Bottle Lid Part# 2 Oil Pipe Part# 3 Tubing Connector Part# 4 Connector Ferrule Part# 5 E type Circlip Part# 6 Compression Nut Female Part# 7 Compression Nut Male Part# 8 Olive Part# 9 Oil Non Return Valve

100mm = 4"inches

supply the right size muffler.


Rev3 May 2019

3

What oil to use

RVS Pumps recommends

T68 ISO for lubrication

you can substitute it with

Winter use and 20W-50 for Summer operation.

Adjust small hexagon head or blue plastic cap for desired drip rate .

First 50-75-100Hrs

Our pumps are Fully Run In but it is advisable to follow

the recommended drip rate for a new pump as shown on this page.This will ensure that the pump obtains a perfect Vane Seating and a mirror finish in the bore.

NEVER use Vegetable OilHydraulic Oil - Brake-Fluid Gear Oil - Transmission Fluid

Unspecified Vac - pump Oils

What damages your pumpThe contaminants such as washing detergents, solvents other certain chemicals will seriously affect the quality and viscosity of the oil that you are using.

carbon fibre (Kevlar) material and while they are extremely strong they could be affected by the above chemicals and cause them to swell and jam in their rotor slots.To stop

into the neutral running pump

Oil Drip-rate Adjusting Valve

LUBRICATION

M3000 - M4000 - M7000

After:1drop every 2 - 3 secFirst 50hrs 1 drop / second

M9000 - M10000 Pump

After:1drop every 2 secondFirst 75hrs 1 drop / second

M12000 Pump

After:1drop every 2 secondFirst 100hrs 1 drop/second

Pump vanes are made from

Steam Turbine Oil T46 or

If you have difficulties buying Steam Turbine oil T68 or T46

Diesel engine oil 5W–30 for

this situation arising slowly pour Diesel fuel once a week

to keep the vanes and bore

detergents and solvents.clean and free of chemicals


Rev3 May 2019

4

1. The pipework must be completely clean, dry and free from internal rust or scale. 2. When fitting the inlet and exhaust pipework it is essential that adequate support is provided and that the pipe is properly aligned to prevent excessive strain being placed upon the pump. 3. During installation leave the clear dust protectors on the Inlet and exhaust ports in place to ensure no foreign matter enters the pump and cause serious damage during first start up. 4. It is Mandatory requirement to fit a pre-filter onthe intake side to prevent any particles from entering the pump. 5. Use Teflon pipe tape as the only jointing medium since surplus from liquid jointing compounds will damage the blades if drawn into the pump 6. When the pump is exhausting from a receiver or working with a system having a large storage capacity, it is essential to fit a non-return valve preferably in front of the pre-filter thus preventing the pump from running in reverse.

7. Arrange both the inlet and exhaust pipework to ensure that any condensate flows away from the pump. 8. AIl pipework and fittings must comply with Australian or the national standard for the country of installation. 9. Fitting Pulleys & Couplings Under no circumstances should pulleys or couplings be driven onto the pump shaft or the electric motor shaft with a hammer or mallet. Apart from being a bad engineering practice it can cause irreversible damage to your pump and or electric motor! We recommend the use of pulleys & couplings fitted with taperlock inserts. 10. Drive coupling Alignment There are three basic modes of misalignment; these are angular, parallel and axial lineup errors. a. Remove any dirt, oil, etc. from all mating surfaces. Place taperlock insert in hub and match half holes on both shafts. b. Place setscrews loosely in threaded holes. Mount assembly in desired position on shafts.

Preparation and pump installation


Rev3 May 2019

5

c. Tighten setscrews. Place the coupling in position, and bring the shafts together obtaining the manufacturers assembled length for the coupling given in their instructions. d. How to check for angular

alignment: Rotate coupling through 90 Degrees and measure the distance between the faces. Repeat adjusting the shafts until four identical measurements are obtained.

e. How to check for parallel alignment: Place a straight edge across the coupling. The hubs will be in correct alignment when the straight edge contacts the 4 points squarely.

11. Drive Belt alignments. Remove any dirt, oil etc from all mating surfaces. Place the taperlock insert in hub and match half holes on both shafts.

a. Mount assembly in desired position on shafts ensuring both shafts are parallel and in correct alignment, use a straight edge, a correctly aligned drive will contact both pulleys squarely.

Straightedge must touchall 4 points on pulleys.

b. The belts should be tensioned towards the high side, to allow for the tension drop after the belts have been run-in. Belt tension should be checked daily in the first week after installation. Warning: Excessive belt tension can damage the pump/motor bearings and could lead to metal fatigue and pump and or motor shaft breakage!

Pre Start-up Checks

Before starting the pump for the first time after installation make the following checks: 12. Ensure all the anchor base bolts are securely


Rev. May 2019

6

fastened. Check the pump is free by turning the shaft by hand a few revolutions. 13. Flick Start the motor to check that the direction of rotation agrees with the arrow on the pump body. Never let the pump run in the wrong direction for any length of time. It can damage your pump instantly.

14. Recheck coupling/drive alignment and retention. Ensure all equipment is installed and earthed in accordance with current standards and legislation.

15. Check that the shaft protector is fitted.

16. Remove the clear dust protectors from both the Inlet and Exhaust ports.

Start-up

17. Start the drive motor and bring the pump up to operating speed. Check that vacuum is generated and holding. Adjust the regulator (Dairy) or the vacuum relieve valve (Liquid Waste) to the desired setpoint. Adjust the Visifeed drip rate to that indicated in the lubrication section.

Check all protective devices and controls, making sure they are working correctly. 17. Earthing:

It is most important that the motor and pump are properly earthed for the safety of the operator especially in wet places like Dairy installations All electrical installation must be carried out only by authorized personnel! Belts can become electrostatically charged and must never be used in explosive atmospheres!

Before replacing an old Vac Pump with a new one it is important to follow these simple rules. You may think that it is just a simple matter of swapping the new pump straight over and then getting back to work, but it is not. Failure to follow these simple steps can cut short the life of your new pump!!Liquid Waste Truck: After disconnecting your old pump from the tank, assess if you have the following items fitted to your tank.

REPLACING AN

OLD PUMP


Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019Rev. May 2019

Rev3 May 2019

7

Item 5: Secondary Trap Tank

Item 7: Vacuum Relief Valve

Item 9: Pre Air Cleaner

Item description page 9 The reason for above items is simple. The old pump's capacity has been greatly diminished or you would not replacing it. The resulting low airflow means that dirt and scale etc from the inlet side of the pump will be allowed to build up. When the new pump is connected, this sudden large increase in airflow can dislodge the dirt and scale & without the mandatory items all this dirt, scale would be sucked into the new pump, ruin it within a few minutes. The low airflow also means that the exhaust may not have been cleaned thoroughly and may indeed be clogged. The new pump will have higher airflow and the exhaust restriction will cause back pressure and increase the operating temperature of the pump.

lf liquid has entered the pump

IMMEDIATELY

THE PUMP HAS SEIZED

Proceed as follows:

Remove the drive belt and rotate the pump by hand to get rid as much as possible of the remaining liquid. Pour 1 litre of Diesel fuel slowly into inlet port while

rotating the pump at least 20 to 30 times before recommencing work.

If you can’t rotate the pump by hand remove it from the truck lay it on its side and use a water hose to spray water into the port and wash out all traces of the liquid which has entered the pump. Continue for about 4 to 5 minutes.

Empty all water out, fill the pump with Diesel fuel and try to rotate it by hand. If that is successful empty the pump and re-mount it on the truck.

Don’t reconnect the pipes at this stage, start up the pump in neutral and increase the speed while continuously squirting oil into he Inlet port. After about 4 to 5 minutes of running, the pump should be ready for work again.


Rev3 May 2019

COMPLETELY

STOP THE PUMP

8

IF YOU HAVE AN EMERGENCY!

View pump from the side and look directly into the inlet port The loose end cover plate is on the left hand side of the pump.

screws & carefully tap off the endplate. Use a brass bar and hit end plate near the tapered dowels. Alternate hitting the end plate ensures a square removal.

Avoid using excessive blows to the end plate. Make sure the rotor is supported by placing a block of wood under the rotor. Never let the rotor hang unsupported in the bore.

Because of its heavy weight the rotor can damage the assembly side end plate. To avoid this damage we recommend to place the pump on pieces of wood and remove end plate as shown. Inspect the bore, any grooves even small ones on a new pump indicate foreign matter has entered the pump.

Carefully inspect the vanes for damage. They must be

sliding freely in the slot with almost no resistance. Any sign of wear on new vanes indicates insufficient filtering. Ensure that if the same vanes go back into the pump the must go in the same slot and in the same position.

When reassembling, ensure that the special gaskets line up with the dowel and screw holes.

Only when the endplate is sitting down on the housing insert the taper dowels and drive them in for perfect line up. Evenly re-tighten the 8 socket head screws.

Dismantling the pump

Remove all 8 socket head

Remove this end plate

Support hanging rotor


Rev3 May 2019

9

TYPICAL VACUUM TANK SETUP

MANWAY HATCH

MAIN TANK

MAIN TANK

OVERFLOW VALVE

VACUUM GAUGE

DRAIN TAP

NON RETURNVALVE

SHOULD ALWAYSBE A RVS PUMP

OIL CATCHER MUFFLER

SECONDARYMOISTURE TRAP

TANK

VACUUM RELIEFVALVE

PRE AIR FILTER

TYPE AIR FILTER WASHABLE TRUCK

The suction hose is connected to the Inlet Hatch and the valve provides controlled inlet flow and is operated either manually or pneumatically.

The Manway hatch allows tank access for inspection and service repair work.

Normally built for vacuum operation (Sucking only) the tank ends should be

NEVER PRESSURIZE A TANK BUILT FOR VACUUM USE!domed & the tank inside should be adequately reinforced to prevent it from

Will shut off the airflow to the pump when the tank is full. Make sure theball is heavy enough to prevent it being sucked up and stop the pumpingwith the tank only partially full. Regularly inspect the rubber ball seating

Allows the operator to set the most efficient tank pressure with the Vacuum

pipe system, filter #9 or #9A is blocked or you have a worn or damaged pump

Drains away any liquid trapped in the Secondary Trap Tank. It is absolutelyessential the trap tank is drained at the beginning of a new shift! Remember,you have no protection & risk severe pump damage if the tank is full with liquid!

Stops the pump from turning backwards when the pump motor is switched offunder full vacuum. A backward turning pump can not only damage the vanes but also can suck the exhausted dirty oil from the muffler back into the pump.

Ideally the pump should be driven by a separate petrol or diesel engine as a“Stand Alone” system. If you couple the pump to the gearbox PTO, chancesare that in case of a mishap the truck’s gearbox could be severely damaged.

The OIL CATCHER catches the pumps’s waste oil by spinning it out of the airstream and collects it in its tank where it can be drained out by the operator.

The MUFFLER section reduces the pump noise to an acceptable level.

MANDATORY ITEM!! The tank works on a “Cyclonic Principle” wherebymoisture and liquids are spun out of the airstream & dumped into trap tankbefore they can reach and damage the pump. See note on draining below!

MANDATORY ITEM!!MANDATORY ITEM!!

MANDATORY MUST HAVE ITEM! The Pre Air filter is one of the mostimportant items of your installation because it prevents small particles likestones, sand etc being sucked into the pump which could cause serious damage!

In addition to the Oil CATCH MUFFLER Item #11, an additonial Muffler can be supplied Item #12 when very low pump noise levels are required!

2

3

4

5

6

7

8

9

9

10

11

12

Relief valve item #7. Slow rising vacuum could indicate major leakage in the

4 - 6 MICRON

80 -120 MICRON COARSE

1

MUFFLER

Regardless of the type of job like “WET” Septic MANDATORY ITEMI! Tank Cleaning or “DRY” Directional Drilling or Condensate removal from tanks this filter ensures only totally clean air enters your vacpump for absolute protection.

a

Prevents vacpump pressure going over a presetlevel. Normal operation -65 to -70Kpa but never higher than -75Kpa. If set higher, blocked hoses or filters will cause severe overheating damage to pump!

ADDITIONAL

becoming “Sucked In”

7 a Additional Valve

RVS Technical DepartmentCopyright: The content of this publication can not be

from RVS Pumps Pty.Ltd.copied in part or whole without the written permissionRVSVacPumps

INLET HATCH

1 a

Recommended SETUP VACUUM ONLY operation

10

8

5

6

..

..

.. 4

1

11

Manway

3

For pump lubrication

SHELL TURBO 46 or 68STEAM TURBINE OIL

or equivalent!

RVS recommends

7a

9a9

Additional Relief Valve

Additional Item #7a isfitted to prevent pumpoverheating in case ofa blocked filter. Shouldbe set to max -70Kpa2

3

12

7Hatch

MAIN TANK200 to 26000 Ltr

SUCTION HOSE INLET

INLETHATCHWITH

VALVE

1

a

GATE

10RVS VacPumps Pty LtdSalisbury SA 5108Tel: +61 (0) 88285 5800 [email protected]

Rev3 May 2019

Rev4 June 2019

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16

• Contact RVS immediately the pump has stopped working.

• Make sure the pump is still within the warranty period.

• Make sure the pump has its ID plate attached and the serial number is legible to qualify for warranty consideration.

• The pump must be returned to RVS prepaid and in its original condition for us to carry out a detailed inspection.

• RVS will determine if a genuine claim exists and if we approve it the pump will be replaced or repaired to its original condition.

.Procedure for making a Warranty claim.

WARRANTY

Factory address:RVS Vacpumps17 Fisher Street

Salisbury SA 5108Australia

17

Please read this manual

most out of your pump.It will help you to get the

Still have questions?

very carefully

Call the RVS Team61(0)882855800

Email:[email protected]

Documents

Web Operation Manual August 2019 - RVS Pumps