BeaconMedaes VerusLab 4107 9021 88, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions VerusLabTM Lubricated Rotary Vane Laboratory Vacuum System Part number 4107 9021 88 Revision 01 March 04 2019...

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Page 3: ...ed Model number Serial number Option s included Any information service or spare parts requests should include the machine serial number and be directed to BeaconMed s 1059 Paragon Way Rock Hill SC 29...

Page 4: ...Intake Valve Actuator 2 4 2 8 Exhaust Piping 2 4 3A 0 Start Up TotalAlert Embedded Controls TAe 3A 1 3A 1 Prestart up 3A 1 3A 2 Initial Start up 3A 2 3A 2 1 Lubrication 3A 2 3A 2 2 Pump Rotation 3A 2...

Page 5: ...4 4A 4 5 Next In Line Alternation outside normal function 4A 4 4A 5 Backup Vacuum Switch Set Point Adjustments 4A 5 4B 0 General Operation PLC 4B 1 4B 1 Vacuum Control System 4B 1 4B 1 1 System Descr...

Page 6: ...5 3 Oil Leak 6 6 7 0 Replacement Maintenance Parts 7 1 8 0 Maintenance Record 8 1 Appendix A TotalAlert Embedded TAe A 1 A 1 Board Configurations A 2 A 2 PCB1 5 7 Display Controller A 2 A 2 1 Basic So...

Page 7: ...hutdown Screen A 11 A 4 Password Access A 11 A 4 1 Main Screen Password Items A 12 A 4 2 Unit Screen Password Items A 12 A 5 Testing Alarms A 12 A 6 Maintenance A 12 A 6 1 Maintenance Screens A 12 A 6...

Page 8: ...p A 16 A 7 9 System Trend Setup A 16 A 7 10 Electronic Notification Setup A 17 A 7 11 Navigating the Website A 17 A 7 12 Available for Download A 20 Table of Contents continued Lubricated Rotary Vane...

Page 9: ...ing or servicing any covers guards fittings connections or other devices Notify appropriate facility personnel if repairs or maintenance will a ect available vacuum levels This is a high speed rotatin...

Page 10: ...all BeaconMed s products WARNING The vacuum pump may be contaminated with dangerous foreign materials Use personal protective equipment protective gloves protective eyewear protective respiratory equi...

Page 11: ...power quality should be that of a typical commercial or hospital environment Voltage dips short Interruptions and voltage variations on power supply input lines IEC 61000 4 11 5 UT 95 dip in UT for 0...

Page 12: ...rmined by an electromagnetic site survey a should be less than the compliance level in each frequency range b Interference may occur in the vicinity of equip ment marked with the following symbol NOTE...

Page 13: ...all removed electrical connections for easier re assembly at the final destination Tipping the pump over can cause oil to flood the cylinder Whenever the pump is transported be sure to drain the oil...

Page 14: ...k Do not operate vacuum pump on a voltage other than the voltage specified on the control panel nameplate All customer wiring should be in compliance with the National Electric Code and any other appl...

Page 15: ...e connecting any piping the plastic thread protectorinstalledintheconnectionportmustbe removed We recommend that the main vacuum line to the receiver should not be reduced below that provided on the r...

Page 16: ...t be installed on each exhaust port of the vacuum pump before connecting to the main exhaust line leading outdoors Additionally a drip leg must be installed at each exhaust port connection to allow fo...

Page 17: ...5 1 5 1 5 1 5 1 5 2 2 5 Hp1 1 25 1 25 1 25 1 25 1 5 1 5 2 2 2 2 2 2 2 5 Hp2 2 2 2 2 2 2 2 2 2 2 3 3 3 7 5 Hp 2 2 2 2 2 2 2 3 3 3 3 3 3 10 Hp 2 2 2 2 3 3 3 3 3 3 3 3 3 15 Hp 3 3 3 3 3 3 3 3 3 4 4 4 4 2...

Page 18: ...ds the minimum pipe size In this case it does select the next larger pipe size from the table D 4 E To double check the pipe size recalculate the SPL with the new diameter SPL D 4 130 6 x 10 0 190 ft...

Page 19: ...roper operation Refer to labeling on valve handles Remove all packing material from the unit Check the electrical connections to the control cabinet Verify electrical service Before starting the syste...

Page 20: ...al override OFF position This is indicated by the middle position X on the three position sliding switch as shown in Figure 3A 1 CAUTION Complete the prestart up procedure before continuing with the i...

Page 21: ...Pump Mode on the Unit touchscreens are still in the OFF position see Figure 3A 2 and 3A 3 See Appendix A for complete list of Screen Toolbar Descriptions 3A 2 3 Direct On Line or Wye Delta Starting Ch...

Page 22: ...quantity DO NOT OPEN THE FILLER PORT WHILE THE PUMP IS RUNNING After testing each pump if everything appears normal put each pump into the AUTOMATIC mode and allow each pump to run until vacuum build...

Page 23: ...ss stream 2 The purge solenoid valve opens and allows fresh air to enter the pump Make sure that the manual adjustable purge valve on the inlet side of the purge solenoid valve is used to set the rate...

Page 24: ...are positioned for proper operation Refer to labeling on valve handles Remove all packing material from the unit Check the electrical connections to the control cabinet Verify electrical service Befor...

Page 25: ...the motor of the specific pump that is to be checked by momen tarily turning the switch to HAND and then pressing the emergency stop button Turn the Hand Purge O Auto back to PURGE OFF and then twist...

Page 26: ...ILE THE PUMP IS RUNNING After testing each pump if everything appears normal put each pump into the AUTO mode and allow each pump to run until vacuum builds Check for any leaks in the piping Repair le...

Page 27: ...e inlet side of the purge solenoid valve is used to set the rate of air that passes through the purge system during a purge cycle Set the manual adjustable purge valve to a point where the pump achiev...

Page 28: ...receiver tank Once the vacuum level drops to the first virtual pressure switch the control system will signal the lead pump to start Virtual pressure switches are system defined pressure levels based...

Page 29: ...ge system is used to reduce the e ect of corrosive process gas While the pump is running to meet demand the inlet electric actuator isolation valve is open and the purge solenoid valve is closed Once...

Page 30: ...pump into AUTOMATIC mode to make the pump available for operation High Discharge Exhaust Temperature Shutdown This will shut down the vacuum pump in question and not restart until the condition is cor...

Page 31: ...his can happen due to the run timer not having expired even though the lag vacuum level itself may be above the alarm setting The Lag Alarm will activate if the vacuum transducer signal circuit is los...

Page 32: ...backup vacuum switch should always be set with falling vacuum level starting at a vacuum level higher than the setpoint 3 Using the vacuum gauge determine the actuation point of the switch 4 If the ac...

Page 33: ...2 The PLC monitors the system vacuum switch condition starts and stops the pumps depending on changing vacuum switch conditions and run timevalues andautomaticallyalternatesthelead position between u...

Page 34: ...xt pump will start followed by the next pump until all pumps have started The time delay prevents high inrush current after a power failure or emergency power switch over During this initial system st...

Page 35: ...uum level drops to where a pump is needed the pump will come back out of purge and start running again In either case the inlet valve will open and the purge solenoid valve will close The manual adjus...

Page 36: ...to come on For example in a quadruplex system if all four 4 H P O A switches are set to AUTO then the lag alarm will trigger when the fourth unit comes on If on the same system three 3 of the four 4 H...

Page 37: ...crew clockwise lowers the cut in and cut out vacuum settings equally 2 Adjust the di erential screw B to the required cut out vacuum setting Turning the screw counter clockwise will increase the cut o...

Page 38: ...tamination Disassemble valve plate assembly clean re place worn or damaged parts and reassemble Oil tank is low empty of oil Immediately shut o the pump drain the remaining oil from the tank and reple...

Page 39: ...e pump to determine reason Replace all necessary parts Clogged exhaust oil separator s back pressure too high Replace separator s Ambient temperature too high Reduce ambient temperature Unit runs roug...

Page 40: ...resh oil If an incorrect oil type or contamination is found make sure the pump has reached its operating temperature before replacing with new fresh oil Refer to Section 6 2 for the cor rect type of o...

Page 41: ...ed if this pressure is near 0 7 bar or greater ap proximately 10 psig Pump is overfilled with oil Adjust oil level to proper setting or replace oil with the correct type Refer to Section 6 2 for the c...

Page 42: ...has tripped Check voltage at the pump to see if one leg of the three phase is out Evacuation purge of the sys tem takes too long or is too short Adjustable purge timing not set appropriately for the...

Page 43: ...s Check Monthly Replace Annually or as needed Inspect Replace the inlet filter elements Inlet filter screens inlet fil ters Check Monthly Replace Annually Clear as required Motor bearings 1 5 10 HP mo...

Page 44: ...l changes will provide better lubrication at high operating temperatures and will prolong the life of the exhaust filter elements 6 1 1 Vacuum Pump Maintain the pump regularly to achieve the best oper...

Page 45: ...nt temperatures above 105 F Oil level readings should be done only when the pump is turned o Oil can be added to the oil fill port if the pump is shut o and the circulating oil has su cient time to re...

Page 46: ...ring failures are caused by dirt introduced by greasing than from insu cient grease Be careful not to over grease the motor If this occurs the excess grease will spill out of the motor and drip onto t...

Page 47: ...ke sure that the ba e strainer touches all sides of the exhaust box Insert the distance sleeve 137 into the two grooves This holds the sheet metal plate and ba e strainer in place Inspect the exhaust...

Page 48: ...ecure the exhaust cover end plate 140 to the exhaust box using eight hex head cap screws 142 and eight lock washers 143 For 15 Hp 20 Hp and 25 Hp To replace the exhaust filters unscrew the screws 142...

Page 49: ...Figure 6 2 Exhaust Filter 1 5 Hp through 5 Hp RA0100 Figure 6 3 Exhaust Filter 5 Hp RA0155 Lubricated Rotary Vane Laboratory Vacuum Systems 4107 9021 88 01 6 7...

Page 50: ...igure 6 5 Exhaust Filter 15 Hp RC0400 20 Hp RC0605 through 25 Hp RC0630 Figure 6 4 Exhaust Filter 7 5 Hp RA0205 through 10 Hp RA0305 Lubricated Rotary Vane Laboratory Vacuum Systems 4107 9021 88 01 6...

Page 51: ...ter O ring Cover gasket Purge inlet filter element 2 Year Extended Service Kits 4107 4002 07 Unit Kit Extended Service Kit Size A 1 per pump 1 5 2 Hp Coupling insert 4107 4002 31 Unit Kit Extended Ser...

Page 52: ...pump 7 5 10 Hp Oil Filter Vacuum Oil Synthetic 4107 4001 98 Unit Kit 2 000 Hour Oil Change D 1 per pump 15 Hp Oil Filter Vacuum Oil Synthetic 4107 4001 99 Unit Kit 2 000 Hour Oil Change E 1 per pump...

Page 53: ...e Date of Service Hours Load Ambient Temp Vacuum Level Inlet Filters Purge Filters Inlet Screen Oil Change Oil Filter Motor Bearings Coupling Inserts Exhaust Filters Relief Valves Misc Serviced By Lub...

Page 54: ...n Date Date of Service Hours Load Ambient Temp Vacuum Level Inlet Filters Purge Filters Inlet Screen Oil Change Oil Filter Motor Bearings Coupling Inserts Exhaust Filters Relief Valves Misc Serviced B...

Page 55: ...rcuit Boards Proximity Sensor Unit Screen 1 Unit Screen 2 Power ON Light Alarm Buzzer RS 485 Power 6 Conductor Cable PCB4 Pump Customer Ethernet PCB3 PCB4 Mounted on Back Panel Ethernet Network PCB2 U...

Page 56: ...the Master Controller Board PCB3 via a RS 485 bus to relay commands from the touch screen interface and display messages from the master controller 2 Interface to the 5 7 Display touch screen to inte...

Page 57: ...ar to allow the user to check display board PCB1 version information If the connecting board is incompatible with the display board for example board not properly connected only the bottom version but...

Page 58: ...mbol shows X If the unit is unavailable because the unit is an expandable unit that color bar shows dark grey and the adjoining symbol shows E If the unit is unavailable because the unit cannot be rea...

Page 59: ...Ambient Display the current ambient temperature When the button is pressed the trend information is available for this temperature A 2 7 5 7 Maintenance Screen The maintenance screens Figure A 9 are...

Page 60: ...shuts the unit down Shutdown events are latched and are not cleared until the condition is corrected and a user presses the reset button on the unit shutdown screen See Section A 3 9 for details Unit...

Page 61: ...tment of system vacuum operating range Audible Allows the horn to re initiate if an alarm or shutdown event has not cleared but the horn was silenced The allowable values for re initiate time are neve...

Page 62: ...other func tions include the following 1 Communicate to the Pump Controller Board PCB4 via a RS 485 bus to relay commands from the touch screen interface and display messages from the pump controller...

Page 63: ...Green Unit Running Purge O Red Selected Grey Unselected O Red Selected Grey Unselected Manual Blue Standby Backup Vacuum Switch is not closed Grey Unselected Green Unit Running A 3 5 3 5 Main Screen...

Page 64: ...e is started the unit will first delay for 5 seconds to allow the user to get in position to check the rotation then run the unit for a brief period Diagnostic Depicts the I O status of the connecting...

Page 65: ...at given unit A 4 Password Access The TotalAlert Embedded control system con tains items that can be changed or adjusted Be fore making any changes on the system or unit screens a password prompt appe...

Page 66: ...ct method for displaying alarms shutdowns Operator can change the timer setting for sleep mode on the screens A 4 2 Unit Screen Password Items In the Service section of the Unit screens the op erator...

Page 67: ...s on the list appears in red the overdue Service Activity is a System maintenance item If one of the Unit numbers in the bottom right cor ner appears in red the overdue service activity is related to...

Page 68: ...g the fixed IP configuration A 7 4 Set Up Connecting to the Embedded Website of the Vacuum System 1 Start a web browser such as Microsoft Inter net Explorer 2 Enter the system s IP address in the brow...

Page 69: ...ry defaults are Username new Password new 4 The left sidebar will now contain the setup links Figure A 31 A 7 6 Device Setup This Device Setup page Figure A 32 is used to configure the laboratory vacu...

Page 70: ...selecting an auto refresh interval the web page will be refreshed automatically keeping all information current during a viewing period 1 Click Website Setup to access the Website Setup page 2 Select...

Page 71: ...intenance alerts An individual may receive both types of alerts 5 Enter an email address in the From box as this will be the sender of the notifications 6 If desired early warning notifications can be...

Page 72: ...the maintenance activities on the Main tenance page Included on the page are the ser vice item the time interval for each time and the part number and description of the service kit required to perfo...

Page 73: ...software descriptions System Trend The System Trend page Figure A 45 displays multiple items on the system mea sured at specified time intervals These items may include vacuum level pump operation and...

Page 74: ...intenance Log System Trend or System Log 2 Click on the link to create a downloadable file located in the upper right above the dis played information 3 Select to view the information on the web page...

Page 75: ...Figure A 48 System Trend Download VSD shown Lubricated Rotary Vane Laboratory Vacuum Systems 4107 9021 88 01 A 21...

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Page 78: ...1059 Paragon Way Rock Hill SC 29730 888 4 MEDGAS 888 463 3427 Fax 803 817 5750 www beaconmedaes com...