RoboVent FlexPro Hi-Vacuum Series, Owner'S Manual

Page 1: ...FlexPro Hi Vacuum Series HVE Series Cartridge Collectors Owner s Manual Installation Operation Maintenance Revised 11 20 20 ...

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Page 3: ...s Manual Installation Operation Maintenance Manufactured by RoboVent 37900 Mound Road Sterling Heights MI 48310 USA 888 762 6836 www robovent com 2020 RoboVent All rights reserved Models HVE 350 80 1 HVE 550 80 2 HVE 950 80 2 HVE 950 80 2 HVE 550 80 2 HVE 350 80 1 ...

Page 4: ...ined staff to perform these tasks If you would like one of our qualified service staff to discuss a customized service plan for your factory don t hesitate to reach out Our team can also discuss the wide array of replacement filter cartridges we have in stock for purchase to maximize your dust collectors efficiency and performance For any technical issues you may experience RoboVent has a dedicate...

Page 5: ... Installation Section 500 Page 25 Start up Commissioning Section 600 Page 27 System Balancing Section 700 Page 31 Operating your FlexPro Collector using the ePad Controls Section 800 Page 33 Maintenance Section 900 Page 45 VFD Maintenance Procedure Section 900 Page 56 Motor Greasing Guide Section 1000 Page 59 Troubleshooting Section 1100 Page 69 Appendix A General Wiring Diagrams Appendix B Parts ...

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Page 7: ...ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL 7 SECTION 100 Important Safety Instructions ...

Page 8: ...t 4 Refer all service matters to qualified service personnel Servicing is required when the unit is damaged in any way including the control panel supply wiring or in the case of excessive filter loading 5 Disconnect power before working on the motor or blower wheel The motor or blower wheel should be disassembled only by a factory authorized technician 6 Risk of serious personal injury or death U...

Page 9: ...SECTION 200 Glossary of Terms ...

Page 10: ...ioning heating or cooling to an unused room or to regulate it for room by room temperature and climate control Delta3 RoboVent s proprietary Spark Arrestor that utilizes cylindrical force and air patterns to extinguish sparks and prevent then from entering a dust collection system Differential Pressure The difference in pressure between the dirty air side of the enclosed plenum and the clean air s...

Page 11: ...th the responsibility of ensuring safety at work and a healthful work environment OSHA s mission is to prevent work related injuries illnesses and deaths Plenum an enclosed chamber where a treated substance collects for distribution as heated or conditioned air through a ventilation system Pulse Cleaning System In RoboVent s FlexPro Dust Collectors dust and fume enters from the side or back of the...

Page 12: ...FD A variable frequency drive setup with pressure transmitters to control the speed of the motor on the dust collector This device regulates the motor speed and increases its speed to compensate for losses occurring within the dust collector primarily filter loading This allows the dust collector to maintain a consistent airflow throughout the life of the cartridge filters while also saving energy...

Page 13: ...SECTION 300 Specifications Features ...

Page 14: ...oltage Supply 480 Volts 60 Hertz 14 Full Load Amps 230 Volts 60 Hertz 28 Full Load Amps 575 Volts 60 Hertz 11 Full Load Amps Control Voltage 24 VDC HVE 550 80 2 Specifications Chart Weight Full 2250 lbs 1020 6 kg Equivalent Filter Area 708 ft2 65 8 m2 Maximum Airflow 520 CFM 80 in w c 884 m3 hr 20 kPa Operating Temperature 10 50 C 50 120 F Cabinet Construction 11 gauge Steel Polyester Powdercoat C...

Page 15: ...95 m3 hr 17 kPa Operating Temperature 10 50 C 50 120 F Cabinet Construction 11 gauge Steel Polyester Powdercoat Compressed Air Requirements Offline Pulse 12 24 SCFM Online Dynamic Pulse 6 35 SCFM 11 m3 hr 6 34 SCFM 5 9 bar 85 psi Compressed Air Connection 3 4 19 05mm NPT Hard Pipe Voltage Supply 480 Volts 60 Hertz 14 Full Load Amps 230 Volts 60 Hertz 28 Full Load Amps 575 Volts 60 Hertz 11 Full Lo...

Page 16: ...into the containment area Blower generates vacuum allowing airflow for machine Clean air exhausts to workshop Particulate collects in containment drum to be emptied during routine maintenance Air is cleaned as it passes through filter Compressed air pulse knocks dust off filter Particulate builds up on filter Contaminated air from process Spark and large particle deflector ...

Page 17: ...omponents Air tank Regenerative motor blower assembly Noise muffler Lifting lugs 20 Gallon particulate containment drum with latches Cartridge filters Compressed air pulse valve Electrical connection Filter clamp mechanism dirty air inlet Hopper Control panel door Filter door Control panel ...

Page 18: ...filter cleaning The on line and off line cleaning cycles are pre programmed for optimal efficiency but can be customized for changes in usage patterns see Figure 3 4 Pulse Cleaning Valves The RoboVent FlexPro Series Collectors utilize a special cleaning cone which optimizes the cleaning pulse by ensuring that the developed overpressure in the filter is even throughout the filter element see Figure...

Page 19: ... the blower see Figure 5 9 Large Capacity Dust Tray Optional Hopper RoboVent FlexPro Series Collectors come standard with a 20 gallon steel drum see Figure 6 An optional 55 gallon drum is available for heavy dust production applications or extra capacity to reduce frequency of dust clean outs Both are designed to capture and store particulate pulsed off the filter cartridges and minimize re entrai...

Page 20: ...ly monitors the airflow Using a VFD it automatically adjusts the RPM of the motor to compensate for filter loading This reduces energy peaks resulting in 20 30 energy savings and extending filter life The VFD is key for a system that is quieter can operate at maximum operating efficiency and saves you money see Figure 9 13 AutoSaver Auto On Off option The AutoSaver feature if equipped allows your ...

Page 21: ...h the Supprex 200 System there is little or minimal clean up after a fire as it is a clean agent The effectiveness of this suppression system is greatly enhanced with the safe sensor smoke detection that is standard on all RoboVent FlexPro collectors Once smoke is detected the unit goes into an emergency alarm state immediately shutting off the blower and activating the motorized dampers to a clos...

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Page 23: ...SECTION 400 Receiving Inspection ...

Page 24: ...specific arrangements are made otherwise Compare the number of items received against the carrier s bill of lading Inspect all items for apparent damage Immediately report any shortages or obvious damage to the carrier and to your local RoboVent Representative call the factory at 1 888 762 6836 or email customer service robovent com When all skids are completely unpacked and uncrated check all ite...

Page 25: ...SECTION 500 Installation ...

Page 26: ...ess es with high vacuum ducting 4 Adjust airflow to ensure effective fume capture Refer to operating instructions Setting the Unit in Place The first step is to set the hopper in the designated area Floor will need to be concrete at least 4 thick and fairly level Bolt hopper to the concrete using concrete anchors provided in install hardware kit Make sure hopper is level and use shims as necessary...

Page 27: ...SECTION 600 Start up Commissioning ...

Page 28: ...dditional charge In order to schedule start up commissioning and balancing the following items must be completed 1 The RoboVent collector must be assembled 2 The electrical must be connected to the collector 3 The compressed air must be connected to the collector a The compressed air line from the shop must go through the air regulator that RoboVent provides before it is connected to the collector...

Page 29: ...pulse valve is operational 6 Check to ensure the fire suppression FM200 tubing is hooked up correctly if applicable 7 Check the FM200 gauge to ensure your suppression tank is charged if applicable 8 Check that the filter differential tubes running from the control panel to the reading ports are correctly connected ensure the filter pressure is reading correctly on the HMI control screen 9 Check to...

Page 30: ... velocity FPM and airflow CFM within the ductwork 17 Check the measured velocity FPM and airflow CFM vs the designed velocity FPM and airflow CFM Verify the CFM at the fume guns 18 Photos will be taken of the RoboVent Collector RoboVent HMI RoboVent Control Panel Delta3 spark arrestor if applicable ductwork install and the customer s cell 19 Record any parts that need to be fixed or replaced if it...

Page 31: ...SECTION 700 System Balancing ...

Page 32: ...t static point 4 Record the elevation of the plant the temperature within the ductwork and the static pressure within the ductwork If these values stray from the standard Standard Elevation 1000 FASL Temperature 90 F Static Pressure 20 w g you must do a density factor correction NOTE To properly balance a high pressure system you must take SP into consideration when calculating the density factor ...

Page 33: ...ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL 33 SECTION 800 Operating your FlexPro Collector using the ePad Controls ...

Page 34: ...stem Control Enables Disables the system for blower control Off is under security A login is required to turn unit off Auto Control Enables RoboVent unit to be turned on or off from a connected machine Login Allows customers to login with their provided User Name and Password to change parameters SERVICE 47034330 ...

Page 35: ...Disables the blower to run the collector Fault Status Message box which shows the current condition for the Motor overload VFD Status Message box which shows the current condition of the Variable Frequency Drive VFD Also allows user to reset when there is a fault Blower Status Message box which shows the current status of the blower ...

Page 36: ...own mode Auto Offline Pulse Message box which shows the current status of the Auto Offline Pulse Cycle On Off Filter Pressure Message box which shows the current status of Filter Pressure in the collector Use the Arrow button to change readout from kPa in W C Auto Online Pulse Message box which shows the current status of the Auto Online Pulse Cycle On Off Pulsing Control Page ...

Page 37: ...tal Machine Hours Display showing the accumulated machine hours Service Hours Reset Service Hours reset button When pushed resets the Service Hours Meter to zero Hours Since Service Display showing the accumulated machine hours since service has been conducted on the collector Unit Hours Page ...

Page 38: ...filters need maintenance Suppression Tank Message Informs the operator that the Suppression Tank needs to be serviced Service Messages Page Collection Drum Message For optional barrel sensor informs the operator that the collection drum is full and needs to be emptied SECTION 800 ePad Controller Operation ...

Page 39: ...ve Alarm Notification Window Date Shows current month day and year Time Shows time when alarm was activated State Shows the current state of the alarm active deactivate and acknowledged Alarm Scroll Navigation Buttons Allows for scrolling up and down by alarm and page Alarm Log Page SECTION 800 ePad Controller Operation ...

Page 40: ...ller Operation System Settings Page Blower Jog Momentary contact to test blower rotation etc Pulse Test Momentary contact that energizes pulse valve Helpful for diagnostics Shut Down Delay Amount of Time in minutes equipment continues to run after the remote start signal ends ...

Page 41: ...SECTION 800 ePad Controller Operation System Settings Page Bar Graph Control High Limit Controls the position of the top pointer Low Limit Controls the position of the lower pointer Scale Maximum Sets the overall range of the display Usually set at 4 00 ...

Page 42: ...life Online Filters are pulsed while unit is running Offline Filters are pulsing after the blower s are shut down Maintenance Filters are pulsed for an extended period for maximum cleaning Delay Time Amount of time in seconds between pulses Pulsing Time Amount of time in milliseconds that pulse valve is open Usually set at 200 msec Note The right hand zero is fixed so enter 200 for 200 Post Cycles...

Page 43: ...fire suppression tank is low or empty Unit will operate without tank being full but it is not advised Proceed Without Servicing When proceed without servicing button is pressed screen is switched to screen 2 Alarm Screen Optional equipment Indicates the fire dampers have been deployed Unit will NOT operate properly until dampers are reset Only press RESET button when dampers have been reset Alarm ...

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Page 45: ...SECTION 900 Maintenance ...

Page 46: ... must be performed by your local waste service provider and dust must be disposed of in accordance with local state and federal law When ladder or lift is required to access the machine disconnect and spark arrestor s during service use proper fall protection equipment and follow all OSHA safety regulations Special Safety Note Stainless steel processes create a hexavalent chromium hex chrome dust ...

Page 47: ...col for discarding contaminated waste 7 Ladder or lift depending on unit location and placement Maintenance Procedure 1 Start the machine and record the starting filter differential pressure once the blower reaches full speed see Figure 16 2 Turn blower off not system off leave system on see Figure 17 3 Offline pulse will start Leave machine for a half hour to allow pulsing to finish This will sen...

Page 48: ...t down into the containment area DO NOT BRUSH THE FILTERS Brushing the filters will cause unseen damage severely shortening the filter life and efficiency 7 Visually inspect filter door gasket Any damaged torn or loose gasket will need to be replaced see Figure 22 8 Close filter door 9 Open dust tray record percentage full for reference to help estimate the frequency needed for proper maintenance ...

Page 49: ... excess noise 15 Record differential pressure of filters once the machine is at full speed 16 If the unit is equipped with a smoke detector see Figure 24 call RoboVent tech support 1 888 762 6836 for assistance and instructions to locate and test 17 Now that all checks have been completed return to normal ready condition by turning blower off indicated by a steady blue light FIGURE 23 FIGURE 24 ...

Page 50: ...ol panel door Lock out see Figure 26 3 Lay out protective floor covering below door area for simplified clean up 4 Open filter door Brush any built up debris from the door area into the hopper see Figure 27 5 Unlatch filters by pulling the two handles on either side of each row toward you see Figure 28 6 Remove filters individually properly containing each filter as they are removed Dispose of acc...

Page 51: ...sket 12 Close filter door 13 Turn power to machine back on 14 Turn system on and start blower 15 Record new filter differential pressure The blower will need some time to ramp up to speed Once CFM and pressure have stabilized the value can be recorded 16 Reset the service hours on the control screen see Figure 30 You will need to login to reset To login User Name SERVICE Password 4703430 a Press t...

Page 52: ...ectly in the center of the page Current User will change from none to SERVICE depending on what you entered f System will notify if data was incorrect g Once logged in press home button Then Machine hours then reset to reset service hours Questions Please call us at 586 698 1800 ask for tech support when in front of the touch screen and I will be happy to review your settings and help change them ...

Page 53: ...ns Dry Chemical Monthly Inspection Inspection by the owner or end user should verify the following 1 The Suppression Unit is in its proper location as installed by the factory or factory certified technicians 2 The Manual Actuators are unobstructed 3 The Suppression Unit shows no physical damage or condition that might prevent operation a This includes inspecting the detection tubing in the hazard...

Page 54: ...an Authorized Firetrace Service Location at least once every 6 years The powder will be examined for caking and may require replacement FM 200 Monthly Inspection 1 Ensure the Suppression Unit is in its proper location as installed by the factory or factory certified technicians 2 Ensure the tank shows no physical damage or condition that might prevent operation a This includes inspecting the detec...

Page 55: ...ing and fittings from the cylinder valve discharge ports s b Immediately install the safety plugs s into the valve discharge port s c Remove the cylinder from the bracket 2 Weigh the cylinder Compare the measured weight with the weight found on the cylinder nameplate If the container shows a loss in agent quantity of more than 5 percent or a loss in pressure adjusted for temperature of more than 1...

Page 56: ...ust measure the AC input output and DC Bus potential to insure safe levels prior to resuming work Failure to adhere to this warning may result in personal injury or death Clean off any dirt and dust with an air gun using clean and dry air at a pressure between 55 85 psi Replace the boards if they cannot be made clean Clean off any dirt and dust with an air gun using clean and dry air at a pressure...

Page 57: ...lay values Key functionality Clean X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Environment Equipment AC Power Supply Conductors Wire Connections Transformers Reactors Terminal Blocks DC Bus Capacitors Relays Contactors Soft Charge Resistors Operation Cooling Fans Fins Heatsink Digital Operator General AC Power Circuit Devices Control Circuits Cooling System Keypad Display INSPECT...

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Page 59: ...ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL 59 SECTION 1000 Motor Greasing Guide ...

Page 60: ...tact that can occur between rotating elements Follow RoboVent s Motor Greasing Guidelines to properly lubricate your electric motor NOTE 1Pump 1gramofgrease OUNCES OZ GRAMS G GREASE GUN PUMPS 0 1 oz 2 835 g 2 8 pumps 1 oz 28 35 g 28 pumps 2 oz 56 70 g 56 pumps 3 oz 85 05 g 84 pumps 4 oz 113 40 g 112 pumps 5 oz 141 75 g 140 pumps Grease Conversion Chart for use with this grease gun Manual Grease Gu...

Page 61: ... polyurea base grease Certain T frame models will utilize special grease and will be noted on the lubrication nameplate Relubrication Time Interval Amounts Fill new grease until it overflows and the old grease is entirely replaced BEARING SIZE MOTOR HP GREASE 1800 RPM 3600 RPM AMOUNT HOUR CHANGE HOUR CHANGE IN GRAMS INTERVAL INTERVAL All motors listed are ODP DE NDE 6306ZZ 5 30 grams 3000 hours 20...

Page 62: ... required 6 Wipe off excess grease and replace filler and drain plugs 7 Motor is ready for operation Approved Greases Chevron SRI 2 Rykon Premium 2 Exxon Polyrex EM Texaco Polystar RB Service Types Seasonal Service The motor remains idle for a period of 6 months or more Standard Service Up to 16 hours of operation per day indoors 100 F max ambient temp Severe Service Greater than 16 hours of opera...

Page 63: ...0 HP 34 grams 440 125 HP 42 5 grams Relubrication Amounts 1800 RPM OVER 1800 RPM 1800 RPM OVER 1800 RPM 1800 RPM OVER 1800 RPM OR LESS OR LESS OR LESS SERVICE CONDITIONS Standard 3 yrs 6 months 2 yrs 6 months 1 year 3 months Severe 1 yr 3 months 1 yr 3 months 6 months 1 month Seasonal The motor remains idle for a period of 6 months or more Relubrication Time Interval NEMA FRAME SIZE IN RPMs 140 18...

Page 64: ... run the motor for 1 minute at full speed 3 Then turn off the motor and pump in the rest of the grease Note The injection of all the grease with the motor in standstill can make the grease penetrate into the motor through the bearing housing inner seal Approved Grease Mobile Polyrex EM Grease Special Note The table below is specifically intended for relubrication with MOBIL Polyrex EM grease and b...

Page 65: ... 20000 hours 364 5T 60 HP 27 grams 3600 hours 9700 hours 404 5T 100 HP 27 grams 3600 hours 9700 hours 444 5TS 125 HP 27 grams 3600 hours 9700 hours RELUBRICATION INTERVALS IN HOURS 324 5T 40 HP 21 grams 9800 hours 20000 hours 364 5T 60 HP 27 grams 4800 hours 9700 hours 404 5T 100 HP 34 grams 3000 hours 6000 hours 444 5T 125 HP 45 grams 2300 hours 4700 hours Relubrication Time Interval Amount of Gr...

Page 66: ...5 Replace the grease drain plug Correct Grease Gun Procedures 1 Use hand operated grease gun not a pneumatic grease gun Pump grease slowly taking 10 to 12 seconds to complete each stroke 2 Apply quantity of grease called for Over lubrication can be as damaging as under lubrication 3 Do not over lubricate motors Over lubrication of a motor can seriously damage it by forcing grease into motor windin...

Page 67: ...000 hours 22000 hours 254 to 286 160 180 25 HP 30 HP 3600 hours 9500 hours 15000 hours 18000 hours 324 to 365 200 225 40 HP 50 HP 2200 hours 7400 hours 12000 hours 15000 hours 404 to 5000 280 315 100 HP 125 HP 2200 hours 3500 hours 7400 hours 10500 hours Note For vertically mounted motors and roller bearings divide the relubrication interval by 2 Relubrication Time Interval NEMA IEC FRAME SIZE MOT...

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Page 69: ...ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL 69 SECTION 1100 Troubleshooting ...

Page 70: ... 6 Check for voltage at the firing solenoid Note that this will be a very quick firing voltage for less than 300 ms Little or no suction across intake Check the following 1 Check motor rotation When the unit is powered down note the rotation of the motor shaft Motor rotation should be as specified in the HVE Hi Vac Machine manual for that particular motor If the rotation direction is incorrect swi...

Page 71: ...r media If oil or moisture exists in the air supply it will transfer to the cartridge 3 In some cases high oil content is introduced in the welding process causing the oil to vaporize This will cause the cartridge filters to load up prematurely In this situation a specialized filter may be needed Call the RoboVent Service Department at 1 888 ROBOVENT 4 Check for re entrainment Run a Manual Pulse D...

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Page 73: ...APPENDIX A General Wiring Diagrams ...

Page 74: ...A 2 ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL APPENDIX A Wiring Diagram ePad Wiring Primary Wiring ...

Page 75: ...ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL A 3 APPENDIX A Wiring Diagram ePad Wiring Schematic PLC Wiring ...

Page 76: ...A 4 ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL APPENDIX A Wiring Diagram ePad PLC Wiring ...

Page 77: ...ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL A 5 APPENDIX A Wiring Diagram ePad PLC Wiring ...

Page 78: ...A 6 ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL APPENDIX A Wiring Diagram ePad VFD Wiring ...

Page 79: ...ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL A 7 APPENDIX A Wiring Diagram ePad Control PLC Wiring ...

Page 80: ...A 8 ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL APPENDIX A Wiring Diagram ePad Control Panel Cartridge Wiring ...

Page 81: ...ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL A 9 APPENDIX A Wiring Diagram ePad Wiring Notes ...

Page 82: ...ate 18 x21 BP 18x21 1 22 10 HP VFD 480 Volts ED 10 480 1 23 30A Panel Disconnect BMD 30 1 24 Auxillary Contact SQDGVAE11 AUX 1 1 25 Primary Fuse ELEC 078 4 26 Jumper 20 Point Blue ELEC 322 0 5 27 Jumper 20 Point Gray ELEC 321 0 5 28 Terminal End Block EPCXDL25 ELEC 771 1 29 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D SHEET 1 OF 2 DRAWN CHECKED QA MFG APPROVED tvempati 4 10 2018 DWG NO HVE 350 ...

Page 83: ...SPECIFIED ALL DIMENSIONS IN INCHES mm 3rd Angle Projection MATERIAL SPEC ASTM A1011 CS TYPE B HOT ROLLED SHEETS 1943 MATERIAL TYPE THICKNESS ASTM A1018 CS TYPE B HOT ROLLED SHEETS 1943 POWDER COAT SPEC ALL POWDER COATED COMPONENTS MUST MEET AAMA 2603 STANDARDS ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF ROBOVENT IS STRICTLY PROHIBITED PROPRIETARY AND CONFIDENTIAL REVIS...

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Page 85: ...APPENDIX B Parts List ...

Page 86: ...B 2 ROBOVENT FLEXPRO HI VACUUM SERIES OWNER S MANUAL APPENDIX B Parts List D J E A L B C I G H ...

Page 87: ... 1 HVE BLR 40HP Motor Blower Wheel Combo E 1 HS 3C 24 Andon Light F 1 HMI DTS HMI Screen G 2 DV 10 TU Pulse Valve H 2 NS SPR 200 Pulse Nozzle I 1 FR 34 Filter Regulator 3 4 J 1 MHG 2 RV 100 Minihelic Gauge L 1 DR HDH 20 004 20 Gallon Drum APPENDIX B Parts List RoboVent Customer Service For replacement parts service or to speak to a representative contact RoboVent at Phone 888 ROBOVENT Email custom...

Page 88: ... 2020 RoboVent Improving Lives through Clean Air 37900 Mound Road Sterling Heights MI 48310 USA ROBOVENT COM 888 ROBOVENT ...