Related Manuals for Dekker Vmax Series
Summary of Contents for Dekker Vmax Series
- Page 1 Installation Operation & Maintenance Manual Oil-Sealed Liquid Ring Vacuum Pump Systems SERIAL NO.:___________________________ July 2016...
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Page 2: Table Of Contents
UBRICATION CHEDULE ) ................................... 32 NLET ILTER IF INSTALLED ........................................ 32 LUID ......................32 ATERIAL AFETY HEETS AVAILABLE UPON REQUEST ..................................33 HANGE ROCEDURE ................................35 TANDARD YSTEM APACITIES ....................................35 RIMING THE DEKKER Vacuum Technologies, Inc. – Vmax/July 2016... - Page 3 ROBLEMS : ....................................41 ACUUM ROBLEMS :..................................41 VERHEATING ROBLEMS :............................... 42 OISE AND IBRATION ROBLEMS : ......................................42 ROBLEMS ..........................43 ROUBLESHOOTING UICK EFERENCE UIDE WARRANTY, REPLACEMENT & RETURN POLICIES ................ 44 DEKKER Vacuum Technologies, Inc. – Vmax/July 2016...
- Page 4 THIS INSTALLATION, OPERATION, AND MAINTENANCE MANUAL MUST STAY WITH EQUIPMENT. PLEASE REGISTER YOUR EQUIPMENT WARRANTY AND START-UP RECORD ONLINE AT WWW.DEKKERVACUUM.COM DEKKER Vacuum Technologies, Inc. – Vmax/July 2016...
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Page 5: Customer Service
Refer to the bill of lading or the gold-colored system information plate attached to the system. Parts should be purchased from the nearest authorized DEKKER representative or from the vacuum pump system supplier. If for any reason parts cannot be obtained in this manner, contact the factory directly. -
Page 6: Introduction
Please review and follow all instructions in this manual before attempting to install, start or operate equipment. The Vmax oil-sealed liquid ring vacuum pump system is equipped with a standard DEKKER Controller. The DEKKER Controller is a microprocessor-based digital controller for use with DEKKER vacuum systems. -
Page 7: Theory Of Operation
THEORY OF OPERATION The DEKKER Vmax oil-sealed liquid ring vacuum pump system includes our high efficiency liquid ring vacuum pump. Minimal maintenance is required due to the absence of wearing parts such as pistons, sliding vanes and internal bearings. The impeller assembly is the only moving part which rotates freely in the casing without metal-to-metal contact. -
Page 8: Initial Freight Receipt And Inspection
The customer should take photos of the system as it arrives and send to DEKKER if there are any issues. Failure to report these issues within the freight carriers’ undiscovered damage window can result in non- acceptance of warranty claims. -
Page 9: Ventilation
For water-cooled vacuum systems it is necessary to check cooling water supply. A proper, consistent water flow must be maintained for adequate cooling. Normal system operating temperature is between 140° - 185° F. Minimum oil temperature should not be below 45°F. DEKKER Vacuum Technologies, Inc. – Vmax/July 2016... -
Page 10: Electrical Preparation
OSHA, National Electric Code and any other applicable local electrical code concerning switches, fused disconnects, etc. DEKKER includes a wiring diagram in the control panel for use by the installer. DEKKER recommends a main disconnect switch be fitted between the vacuum system and the incoming power. -
Page 11: Pipe Connections And Sizing
Pipe Connections and Sizing DEKKER recommends CPVC piping as discharge temps may exceed +170°F. CPVC is rated for 200°F max, and PVC is only rated for 140°F max. Schedule 40 PVC piping is OK for the inlet connections Before installation, remove all protective inserts on the pump suction and discharge. -
Page 12: Cooling Water Piping (Water Cooled Systems Only)
The cooling water outlet connection of the heat exchanger may be fitted with an optional automatic temperature control valve, which regulates the cooling water flow rate depending on pump operating DEKKER Vacuum Technologies, Inc. – Vmax/July 2016... -
Page 13: Electrical Controls (If Included)
Alarm Reset Pushbutton: The alarm reset pushbutton is used to reset an alarm condition when the condition has been rectified. The RESET pushbutton will remove displayed fault on the DEKKER Controller LCD and alarm if alarm condition has been corrected. -
Page 14: Dekker Controller Keypad
DEKKER Controller Keypad The DEKKER Controller text display, buttons, and LEDs are described below. Refer to the diagram below that shows this information. The Lexan overlay on the controller is durable and scratch resistant. Buttons should be actuated with fingers avoiding use of tools or sharp objects. - Page 15 Maintenance Schedule Service History 17) PROGRAM BUTTON Programming menu for Setpoints, Clock, Vacuum Units, Temperature Units, and after purchase options 18) ESCAPE BUTTON Returns to Run / Standby / Stopped screen DEKKER Vacuum Technologies, Inc. – Vmax/July 2016...
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Page 16: Security Access Levels
“Access Locked”. Basic Access is also restored upon powering the controller off and on. Note: Once the DEKKER Controller has no activity for 5 minutes it will default back to Basic Access any changes after the password times out will required password to be re-entered. - Page 17 “High Discharge Temp” will be displayed. In addition, the Run Status light will be orange and will flash on and off. The pump will not be shut down by this warning condition. Standard Warning is 210°F DEKKER Vacuum Technologies, Inc. – Vmax/July 2016...
- Page 18 Time The DEKKER Controller real-time clock may be viewed and changed from within this menu. The correct local time should be entered to insure proper operation time-dependent functions. UP-ARROW / + button and the DOWN-ARROW / - button can be used to set correct time.
- Page 19 After the two leading zeroes, enter the seven remaining numbers that are supplied by DEKKER in the option kit that was sent for the upgrade. After using the UP-ARROW / + button and the DOWN-ARROW / - button on the DEKKER Controller to scroll to the appropriated digit, press the ENTER button to accept each digit of the key code.
- Page 20 This list provides a recommended maintenance schedule along with intervals. The time in hours until the maintenance is due counts down and can be seen on the DEKKER Controller LCD in this area. Proper maintenance is necessary to provide proper performance and can prolong the life of your system.
- Page 21 HISTORY DETAIL. Press ENTER again for the next prior minute DETAIL. To exit FAULT HISTORY DETAIL, press the LOG button to return the FAULT HISTORY LOG. Or, press ESC to return to the main status screen, e.g., STOPPED / AUTO. DEKKER Vacuum Technologies, Inc. – Vmax/July 2016...
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Page 22: Start Up Procedures
Parallel alignment should also be within the following chart allowances. Consult the factory for specific system size alignment. Mono-block units do not require any field adjustment (motors are C-face mounted). DEKKER Vacuum Technologies, Inc. – Vmax/July 2016... - Page 23 0.020 0.094 2.938 DV0450 3750 0.025 0.109 3.500 DV0550 3600 0.025 0.128 4.063 3600 0.032 0.151 4.875 2800 0.032 0.175 5.688 2400 0.040 0.195 6.625 2200 0.045 0.242 7.750 1500 0.062 0.330 10.250 DEKKER Vacuum Technologies, Inc. – Vmax/July 2016...
- Page 24 4. After the proper operating tension has been applied to the belts, double check the following: A) Parallel position of the sheave shafts. B) Correct alignment of sheave grooves. DEKKER Vacuum Technologies, Inc. – Vmax/July 2016...
- Page 25 28.0 30.0 32.0 34.0 400-1000 24.8 31.0 32.0 36.0 Notes: 1. Use approximately 130% of above values to tension a new set of belts. 2. Use closest sheave diameter for sizes not shown. DEKKER Vacuum Technologies, Inc. – Vmax/July 2016...
- Page 26 FILL LINE on the sight gauge. If gauge level is low, do not add oil! Systems are given a full charge of oil at DEKKER factory. Before filling, run unit at normal vacuum conditions for a few minutes, then shut down and fill to correct fluid level.
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Page 27: Shut Down Procedure
The following sequence of operation is a description of how the Vmax oil-sealed vacuum pump system with the DEKKER Controller should operate. The description is general to cover both simplex to multiplex (more than one pump) systems. It is assumed that all start-up procedures have been followed. Ensure that pump reservoirs are filled with oil (See “Start-Up Procedures”,... -
Page 28: System Alarm Conditions
“High Discharge Temp” will be displayed. In addition, the Run Status light will be orange and will flash on and off. The pump will not be shutdown by this warning condition. Standard Warning is 210°F DEKKER Vacuum Technologies, Inc. – Vmax/July 2016... - Page 29 “Motor Overload” Fault If the pump’s motor overload has tripped due to excessive amperage draw, the system will shut down and the display will indicate “Motor Overload” fault on the LCD. DEKKER Vacuum Technologies, Inc. – Vmax/July 2016...
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Page 30: Maintenance
MAINTENANCE As you proceed in reading this section, it will become clear that the “Maintenance Schedule” for DEKKER Vmax oil-sealed liquid ring vacuum pump systems is quite minimal. The use of the service recommendations and PM schedules provided by the DEKKER Controller will alert you when service is required. -
Page 31: Motor Bearing Lubrication (Where Required)
6-12 months 3 months 404-449 1 year 6 months 1-3 months 6 months 3 months 1 month Lubrication Volume Pump NEMA Volume Model Frame (Cubic inches) DV0030-150 182-215 DV0200-450 254-286 DV0550 324-365 404-449 DEKKER Vacuum Technologies, Inc. – Vmax/July 2016... -
Page 32: Inlet Filter (If Installed)
When using Standard Vmaxol it is recommended that the seal fluid be changed every 10,000 hours of operation. When using Synthetic/Food grade Long-life Vmaxol, seal fluid may be changed every 15,000 hours of operation. Extreme operating conditions may require more frequent changes. DEKKER Vacuum Technologies, Inc. – Vmax/July 2016... -
Page 33: Oil Change Procedure
D. Outer Shell Drain (90 Degree Brass Push-Lock Fitting) Sight Glass does not read from this Outer Shell. Before adding oil when you see it low in the sight glass, check for carried-over oil here! E. Heat Exchanger Drain (Hex Plug/Ball Valve) Oil Fill (Reservoir) Prime Pump DEKKER Vacuum Technologies, Inc. – Vmax/July 2016... - Page 34 C. Main Tank Drain (Ball Valve) D. Separator Scavenge Line Drain (90 Degree Brass Push-Lock Fitting) Not Shown; Under Separator Element Housing E. Heat Exchanger. Disconnect Hoses/Piping to Drain Prime Oil Fill Pump (Reservoir) DEKKER Vacuum Technologies, Inc. – Vmax/July 2016...
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Page 35: Standard System Capacities
Complimentary Oil Analysis DEKKER offers oil analysis to customers, regardless of the age of their system, at no charge. Collect approximately 4 fluid ounces from the machine, and secure it in any type of clean bottle. On the bottle or a packing list, please include the following: system serial number, the type of oil, the run hours on the oil and machine, and note any problems you are having with the system if applicable. -
Page 36: Seal Fluid Strainer
Replace the element every 10,000 hours or once a year. Earlier replacement may be necessary when the back pressure is higher than 4 psig as displayed on the DEKKER Controller. High back pressure is a result of dirt build-up on the separator element due to oil varnish or contaminated inlet gas stream. -
Page 37: Maintenance Schedule
10,000 Hours of Operation Or once per year, change seal fluid. Use DEKKER Vmaxol seal fluid. Life of Standard Vmaxol is 10,000 hours of operation. Synthetic/Food grade Long-life Vmaxol may be changed every 15,000 hours of operation. ... -
Page 38: Accessories And Protective Devices (If Included)
High Temperature Shutdown: will signal when the temperature of the oil is exceeding the shut- down level. The DEKKER Controller will shut the unit down and the High Disch Temp shutdown will appear on the DEKKER Controller LCD. The unit will not restart until the alarm condition is acknowledged and is reset. - Page 39 If the level switch is triggered, the affected pump will shut down. The LOW OIL LEVEL shutdown will appear on the DEKKER Controller LCD. The low level switch will be wired into the DEKKER Controller. The alarm will have to be reset to restart the pump. When...
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Page 40: Troubleshooting
Facing the back of the DEKKER Controller, this is the upper connector on the right side of the board. The lowermost terminal on this connector is +24VDC while the next terminal above is GND/-24VDC. If 24VDC is not present at the controller terminals, next check at the + and –... -
Page 41: Vacuum Problems
Check if the pump has seized by rotating the coupling by hand (disconnect power first). If a rubbing noise or binding is observed, contact authorized dealer. Check high temperature setting on the DEKKER Controller Program Menu, which should be set for 225 refer to page 13. -
Page 42: Noise And Vibration Problems
Check if the inlet valve is closed. The pump will hydraulically knock / cavitate if inlet is closed. Check vacuum level on the DEKKER Controller LCD. Pump could hydraulically knock / cavitate as a result of a too high vacuum level. -
Page 43: Troubleshooting Quick Reference Guide
Troubleshooting Quick Reference Guide DEKKER Vacuum Technologies, Inc. – Vmax/July 2016... -
Page 44: Warranty, Replacement & Return Policies
Installation, Operation, and Maintenance (IOM) Manual. If purchaser elects to use a non-DEKKER seal fluid, which has been approved by DEKKER, product warranty may be reduced (as noted below). If purchaser elects to use a non-DEKKER seal fluid, which has NOT been approved by DEKKER, product warranty may be void. - Page 45 No allowance will be granted for repairs or alterations made by the purchaser without the DEKKER’s written consent. In lieu of the foregoing remedy, DEKKER may (if DEKKER so elects), redesign and/or replace the product or refund the full purchase price thereof.
- Page 46 Return for Replacement (incorrect part number received due to DEKKER shipping error): New purchase order is required to release correct items. DEKKER After Sales Associate will issue RMA for incorrect items. Upon receipt, if product is returned in good condition, the original order will be credited in full.
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