SUPAVAC SV110 PUMP MANUAL VERSION 1.0 DATE: 12/05/2007 Head Office: 4/15 Cessna Drive, Caboolture QLD. Australia 4510
Views 198 Downloads 3 File size 2MB
SUPAVAC SV110 PUMP MANUAL VERSION 1.0
DATE: 12/05/2007
Head Office: 4/15 Cessna Drive, Caboolture QLD. Australia 4510 Phone: 61 7 54955477 Fax: 61 7 54955244 E: [email protected] W: www.supavac.com
INDEX Safety
Page 3
1. Oprational Overview
Page 4
2. SV110 Set-up
Page 5
3. SV110 Operation
Page 7
4. SV110 Timers
Page 8
5. SV110 Accessories
Page 10
6. SV110 Troubleshooting
Page 11
7. SV110 Maintenance Procedures
Page 12
Page 2 of 15
SAFETY FIRST CAUTIONS AND GENERAL SAFETY This manual contains important information concerning installation, operation and proper maintenance of the Supavac SV110 Solids Pump. To prevent injury to personnel or equipment damage, this manual should be read and understood by those responsible for the installation, operation and maintenance of the equipment. •
Isolate, Tag Out and Disconnect the air supply to the unit prior to working on any part of the system.
•
Lift the equipment only at the certified lifting points detailed in this manual. Use properly rated lifting equipment capable of handing the equipment weight. CAUTION: Be aware of retained material in the SV110 tank increasing the total weight of the unit.
•
The structure on which the unit is to be installed must be capable of supporting the operational weight of the SV110. Total operational weight of the SV110 = SV110 Dry weight + (110 litres (full capacity of tank) X Specific Gravity of material being pumped).
•
The unit should be installed in a safe area where walkways, lighting and handrails as appropriate allow safe access for operating and maintaining the equipment.
•
Ensure all Hoses and Pipes are in good condition, correctly rated and certified for the service in which they are to be used, correctly fitted and equipped with appropriate retaining straps.
•
Never Weld the pressure vessel section of the SV110 as this will invalidate the certification of the unit. Inspect the unit regularly and replace damaged or worn components only with parts supplied by the OEM.
• •
Ensure all Guards are Fitted Securely prior to use.
•
No Modifications or Alterations to the structure or control circuitry should be undertaken without the prior approval of Supavac PL. Personal injury, machine damage and reduced performance can result from unauthorised modifications or alterations to the SV110.
•
Air Pressure applied to the SV110 should NEVER exceed rated pressure.
Page 3 of 15
WARNING Compressed air can be dangerous. Correctly rated hoses and piping should be used in conjunction with appropriate safety devices on all connections. The unit is not designed to operate above 690kPa (100psi)
Overview of SV110 Operation The SV110 operates as a shuttle system alternately discharging, then loading a wide range of material. Operation is automatic. The SV110 can pump almost any material from heavy slurry through to almost dry material. It has no moving parts in the tank. The SV110 can be wheeled into position under most conditions. Suction lengths of 50m and discharges of 500m are achievable with this pump. It is essential that the correct pressure and quantity of compressed air is available. Incorrect operation will result if inadequate compressed air is supplied to the pump.
SV110 Dimensions Weight - kg Height – Width – Operating Pressure – 690kPa (100psi) Throughput -
Page 4 of 15
SV110 Setup Before operating the SV110 check: a) SV110 is undamaged and cover is in position. b) Clean compressed air at a minimum working pressure of 550 kPa (80psi) and quantity of 120cfm is available at the pump. See Picture 3 for location of pressure gauge. c) 25mm air hose is available. d) All suction hoses, delivery hoses and pickup nozzle are undamaged. e) A discharge area has been chosen for the pump, which will not endanger personnel or equipment. Material from the pump can be ejected long distances from the end of the discharge line. f) The pump does not require an in line lubricator. g) As with any compressed air operated equipment eye and hearing protection is recommended. h) For efficient use of the unit delivery lines should be a minimum of 100mm internal diameter i) Delivery line must be open ended as venturi is back pressure sensitive j) Delivery line must be secured at regular intervals to reduce movement during operation. Check valve
Lift Point
Suction
Air inlet Air valve
Delivery
Jet pack exhaust
Photo 1. Photo showing main components of the SV110
Page 5 of 15
SETUP 1.1
Set SV110 up in a safe and relatively level position near the area to be pumped.
1.2.
Attach suction hose and nozzle to SV110 and ensure safety clips are in place. Position hoses out of walkways.
1.3.
Run out delivery line to the discharge point ensuring there is no danger to personnel from the discharge. Attach delivery hose or pipe to SV110. Position out of walkways. Restrain hose or pipe at regular intervals to ensure it does not move during pumping operations. Quick release fittings on the delivery line are not recommended by Supavac, due to the aggressive nature of the pump discharge. 100mm poly line is an economical discharge line when adequately restrained. Alternately concrete pumping hose or steel pipe can be used.
1.4
Blow out 25mm air hose to ensure it is clean and attach to SV110. Fit safety clips and leave main valve on pump in the off position. Turn air supply on at source.
1.5
Pump is now ready to use
Page 6 of 15
2. SV110 USE 2.1 Ensure discharge area is clear of personnel 2.2 Turn air supply on at the pump. Pump will now begin operation. Dry operation of the SV110 will not damage the pump. The pump always starts in discharge mode (in case vessel was left full from previous operation). The pump is factory set at 10 seconds discharge and 10 seconds suction. This can be varied as required, see later section of manual. 2.3 Slowly introduce nozzle into material to be pumped. Continue operation of pump. Operation is automatic and the pump can be left running unattended indefinitely. However Supavac recommends the pump and all hoses are checked at least once per shift for correct operation. 2.4 Check discharge line to ensure it remains correctly anchored. 2.5 When pumping is complete run the pump for a couple of cycles dry to empty the tank.
Page 7 of 15
3. SV110 Timers
Pressure gauge There should be a minimum of 80psi on this gauge while the pump is operating
Picture 3. shows SV110 timers (cover removed). Arrows indicate reference point for setting timers
The SV110 operates on pneumatic timers. There are no moving parts in the pump. With experience it may be possible to adjust the timers for increased efficiency of operation. Always operate the pump with standard settings until the nature of the material being pumped is fully assessed.
Page 8 of 15
The SV110 timers are factory set at 10 second discharge and 10 second suction. This is a good average setting for most materials. The timers have a scale on them, but to accurately set the cycle times Supavac recommends that the cycles are timed with a watch. As a general rule the following apply: Shorter suction time: • watery/easily pumped material • short suction hose lengths (20m) • vessel is under filling Shorter discharge time: • watery material/easily pumped • short discharge length • majority of the discharge cycle there is no material being ejected Longer discharge line: • thicker materials/mud/slurry • longer discharge lengths (>100m) • discharge line not emptying completely each cycle 3.1 To Change the timer Settings 3.1.1 Turn off air to SV110 3.1.2 Remove cover 3.1.3 Adjust either timer to desired setting. CAUTION: timers only operate in the 0-30 second range. Do Not rotate the timers beyond these settings. 3.1.4 Restore air to the SV110 and check cycle time with a watch. Be aware of moving parts while cover is removed. 3.1.5 Replace cover
Page 9 of 15
4. SV110 Accessories 4.1 Stainless steel pickup nozzle – for ease of operation, attaches to suction hose and allows operator to stand upright. 4.2 Snore box - attaches to suction hose for unmanned operation. Stops large lumps from blocking suction hose. 4.5 Trailer – allows loading of the SV110 and hoses, for high speed or long distance travel. 4.6 Over belt discharge unit – attaches to the SV110 discharge allowing direct discharge onto a conveyor belt.
Page 10 of 15
5. SV110 Troubleshooting Before checking anything else ensure the correct pressure and quantity of compressed air is being supplied to the pump. Pump not cycling correctly
Low supply air pressure
Blocked discharge line Blocked suction line Blocked filter Pump operating correctly but not loading material
Blocked suction line Blocked/Impeded Delivery line Suction hose collapsed or leaking
Blocked Jet Pack nozzle
Pump not operating
Material too viscous for the pump Low supply air pressure
Blocked filter Control system fault
Page 11 of 15
Ensure correctly rated compressor is used. Ensure hoses are correct diameter Unblock suction line as per Section 6.2 Clean or replace filter as per Section 6.3 Unblock suction line as per Section 6.2 Unblock discharge line as per Section 6.1 Replace damaged section of hose. Check all fittings have washers inserted correctly. Clean nozzle and housing as per Section 6.4 Add water to the material as required. Ensure correctly rated compressor is used. Ensure hoses are correct diameter Clean or replace filter as per Section 6.3 Contact Supavac for service.
6. SV110 Maintenance Procedures In use the SV110 requires minimal maintenance. However the following procedures are recommended. Daily: Check pump is undamaged, cover and all safety clips etc. are in position. Check discharge hose is correctly anchored. Check all hoses for damage or wear and replace as necessary Monthly: Check level oil level in lubricator. Top up with air tool oil as necessary. The pump requires minimal lubrication to operate.
Incoming air pressure gauge
Lubricator
Air filter/water trap
Photo 4. Showing air filter and lubricator (cover removed)
Page 12 of 15
6.1 Blocked Delivery Line If the discharge line is blocked the pump will retain pressure as there is a check valve fitted to the suction side of the pump to stop discharge through the suction line in the event of a blocked discharge line. To remove a blockage from the discharge side of the pump: 6.1.1 Turn off air to the pump 6.1.2 Remove cover from pump 6.1.3 Relieve stored pressure in pump by operating the pressure relief valve situated on top of the Jet Pack. (Photo 5) 6.1.4 Carefully remove discharge line and clear the blockage.
Page 13 of 15
Relief Valve
6.4.4 Control hose is located behind the actuator
6.4.5 Clamp
Jet Pack housing
6.4.6 Clamp Photo 5. Showing position of jet pack and relief valve (cover removed)
6.2 Blocked Suction Line If the suction line of the pump is blocked usually there will only be residual vacuum in the line. To remove blockage from the suction line: 6.2.1 Turn off air to the pump. 6.2.2 Ensure there is no stored pressure in the pump 6.2.3 Carefully remove suction hoses( it may be necessary to
Page 14 of 15
apply moderate force to break the vacuum) and clear the blockage. 6.3 Checking or changing air filter
The filter is located under the cover at the discharge end of the pump. (Photo 4) To remove the filter: 6.3.1 Turn off air to the pump. 6.3.2 Remove cover 6.3.3 Ensure there is no stored pressure in the pump. 6.3.4 Unscrew metal cover from air filter housing. 6.3.5 Unscrew clear plastic bowl from air filter. Be careful not to lose the o-ring from top of the plastic bowl. 6.3.6 Remove filter. A screwdriver may be required. 6.3.7 Replace with new filter (available from Supavac) in reverse order. Ensure the o-ring is fitted to the top of the clear plastic bowl. Photo 6. Exploded view of air filter
6.4 Cleaning Jet Pack (See Photo 5) The Jet Pack may require cleaning after prolonged use or if the vessel has been overfilled. To clean the jet pack and nozzle: 6.4.1 Turn off air to the pump. 6.4.2 Remove cover 6.4.3 Ensure there is no stored pressure in the pump. 6.4.4 Remove control hose from the air actuated ball valve. Hose is removed by pushing down on collar where the hose enters the fitting and removing the hose. 6.4.5 Remove clamp from around the middle of the Jet Pack housing. 6.4.6 Remove clamp from the Jet Pack exhaust. Be careful to support the weight of the housing during removal. 6.4.7 Remove the Jet Pack housing and clean as necessary. Ensure the venturi and the opening to the tank are clean. 6.4.8 Replace the Jet Pack housing in reverse order. Ensure gasket/s are in the correct position
Page 15 of 15