SOLIDSVAC SV70-SPDK Manual de usuario

SV70-SPDK Operations Manual

ISSUED DATE - 140421 LAST REVISED - 050821

SOLIDS PUMPING SYSTEMS

V 1.3

U1/ 5-7 Boeing Place - Caboolture - QLD 4510 - Australia

+61 456 000 665 / [email protected] / www.solidsvac.com

CONTENTS

Description

Safety First

1. Operation Overview

2. Design Registration

3. Technical Data

4. Schematic

5. Pump Set-Up

6. Operation

7. Maintenance

8. Timer Cycling & Adjustments

9. Accessories

10. Operation Risk Assessment

11. Parts Assembly

12. Job Safety Analysis

Page

Scan this QR Code for an electronic version of this Operations Manual

www.solidsvac.com

page 3

SAFETY FIRST

CAUTION & GENERAL SAFETY

This manual contains important information concerning the installation, operation and maintenance of the Solidsvac Pump, Model

SV70-SPDK. To prevent injury to personnel or equipment damage, this manual MUST be read and understood by those responsible for

the installation, operation and maintenance of the equipment.

THIS OPERATION MANUAL MUST BE USED IN CONJUNCTION WITH BOTH SITE-SPECIFIC RA AND JSA’s.

- 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 lifting points provided

- The pump should be installed in a safe level area, which provides adequate access for operating the equipment

 - Ensureallhosesareingoodcondition,correctlyratedandcertiedfortheserviceinwhichtheyaretobeused

- Inspect the unit regularly for damaged or worn components

 - AllcoversMUSTbettedpriorandduringoperation

- Air pressure should NEVER exceed rated pressure

 - Tiedownpoints(iftted)MUSTNOTbeusedasliftingpoint

CAUTION: BE AWARE OF RETAINED MATERIAL IN THE TANK INCREASING WEIGHT

SOLIDSVAC PUMPS EACH HAVE SPECIFIC COMPRESSED AIR REQUIREMENTS DEPENDING ON THE JET PACK FITTED.

The operator MUST ensure that an appropriate and adequate air supply is available depending on the model and Jet Pack in use.

AllSolidsvacPumpsrequireaminimumoperatingpressureof500kPaandhaveamaximumoperatingpressureof720kPa(105psi).

Itisrecommendedthata25mm(1”)i.d.airhoseisusedforcompressedairsupplytothepump.

Note: An 18mm (¾”) i.d. Air hose contains HALF the volume of the recommended 25mm (1”) hose.

TheDischargehoseMUSTbenosmallerindiameterthanthepumpsoutlet75mm(3”)preferablyaself-supportingtypeandsecured

at regular intervals.

WARNING: THE PUMP-OUT LINE MUST BE SECURED AT THE EXIT POINT

1. OPERATIONAL OVERVIEW

The Solidsvac SV70-SPDK operates as a shuttle system

alternately loading via vacuum and discharging via pressure

awiderangeofowableandsemi-owablematerials.

Operation is fully automatic and the Solidsvac SV70-SPDK

features no internal workings, high vacuum and pressure

discharge where suction of up to 50 metres and discharges in

excess of 400 metres are achievable.

WARNING

Compressed air can be dangerous. Correctly rated hoses and

piping should be used in conjunction with the appropriate

ttingsandsafetydevicesonallconnections.

Theunitisnotdesignedtooperateabove758kPa(114psi)and

thePRVwillrelieveat758+/-35kPa(110psi+/-5psi).

2. DESIGN REGISTRATION

TheSolidsvacSV70-SPDKhasaCerticateofPlantDesign

Registration from Workcover NSW, Australia. A copy of which

may be obtained by contacting Solidsvac Pumps.

DESIGN REGISTRATION # PV-6-198163/16

Technical Standards

- AS2971-2007 Serially Produced Pressure Vessels

- AS4343-2005 Pressure Equipment - Hazard Levels

- AS1210-1210 Pressure Vessels

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email [email protected]

page 4

3. TECHNICAL DATA

4. SV70-SPDK SCHEMATIC

Height 1150 mm 45”

Width 650 mm 25.5”

Length 1240 mm 48.5”

Weight 130 kg 264 lb

Air inlet 13 mm 1/2” BSP

Suction inlet 75 mm 3”

Discharge outlet 75 mm or 100 mm 3” or 4”

Suction lift 7.9m @ 100 cfm

9.2m @ 180 cfm

11.5m @ 230 cfm

26' 2" @ 100 cfm

30' @ 180 cfm

37' 7" @ 230 cfm

Air consumption options 2.8 m3/Min Jet Pack

5.0 m3/Min Jet Pack

6.5 m3/Min Jet Pack

100 cfm Jet Pack

180 cfm Jet Pack

230 cfm Jet Pack

Delivery 400+ m 1312+ ft

Displacement cycle 65 ltr 17 gal

Operating pressure 7bar(max)@690kPa

4.5bar(min)@448kPa 100psi(max)

65psi(min)

Maximum solids 50 mm 2”

Measured water throughput 400 lpm 106 gpm

TECHNICAL DATA METRIC US IMPERIAL

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page 5

5. PUMP SET-UP

Before commencing operation, Solidsvac strongly recommends each user reads the Operation Manual supplied with each unit and

available online or via the QR code on pump.

Note: No training is necessary to operate the SV70-SPDK however understanding the Operations Manual is essential to safe

practice.

Solidsvacalsorecommendsthatasite-specicRiskAssessment(RA)ofthepumpingoperationisundertaken.Anyrecommendations

arising from the Risk Assessment would be additional to the following:

 - Theunitandallhosesandttingsareundamagedandingoodworkingorder.

 - Allcoversarettedinplaceandcorrectlysecured.

 - Cleancompressedairatminimumworkingpressureof690kPa(100psi)isavailable.

 - A25mm(1”)i.d.airhoseisavailable.

- The discharge area has suitable warnings to protect personnel.

- The correct PPE is available and worn for operating compressed air equipment

- Eye Protection

- Hearing Protection

- Gloves

- Safety Boots

- Set the Solidsvac Pump in a safe level location as close to the material to be pumped as possible.

- Attach both suction and discharge hoses along with any accessories as required and ensure safety clips are in place.

 - Ensurethemainairvalveisintheoffpositionandattachthe25mm(1”)airhosetotheSolidsvacPump&tsafetyclips.

- The pump is now ready for use.

Note: Always position hoses out of walkways where possible remaining aware of trip and fall hazards.

CONTENTS EXCLUDED FOR PUMPING

Solidsvac recommends that any contents that fall within the scope of the below class liquids should not be pumped with any

Solidsvacunit.Solidsvacalsorecommendsthatasite-specicJSAshouldbeconductedwithreferencetoanyothertypeofmaterial

being pumped.

 - ClassIIIAliquidswithaashpointequaltoorgreaterthan140°F(60°C),butlessthan200°F(93°C)haveaNFPA704

ammabilityratingof2.

 - ClassIIIBliquidswithaashpointequaltoorgreaterthan200°F(93°C)haveaNFPA704ammabilityratingof1.

OPERATING PARAMETERS

TheSolidsvacSV70-SPDKcanoperatewithinenvironmentsrangingfrom0°Cto50°Candallhumidity.

ThemaximummediumtemperatureallowablefortheSV70-SPDKis50°C.

HOSES

Solidsvacrecommendsthehoses(AirSupply,Suction,Discharge)usedinoperationwiththeSV70-SPDKaretobemadeofanti-static

material. If the hoses used in operation with the SV70-SPDK are not made of anti-static material, they MUST be braided to comply with

requirementsforFireResistance&Anti-Static(FRAS)toAS/NZS2660,orotherequivalentstandard.

EARTHING POINT

AllSolidsvacmodelsarettedwithanEarthingPointwhichismandatoryrequirementpriortooperation.Solidsvacstrongly

recommends that the operator takes the necessary measures to earth the unit prior to operation.

WARNING: TO AVOID POSSIBLE ELECTROSTATIC CHARGES PRODUCED BY THE MATERIAL CONVEYED THE

OPERATOR MUST EARTH THE UNIT PRIOR TO OPERATION.

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page 6

6. OPERATION

Turn the air supply valve ON at the source. Turning the pump valve to ON, the pump will now commence its cycle of operation. The

LOAD and DISCHARGE cycles are controlled by adjustable pneumatic timers, these allow for adjusting the pump to varying conditions,

i.e.heavyorlightmaterialorlongorshortdistancesetc.DuringtheLOADcycletheoperatorshouldnoteanaudibledifference(Gargle)

oncethevesselhaslled,adjusttheLOADtimertowherethecyclecompletesjustasorpriortothisoccurring.TheDISCHARGEcycle

depends on both the material being transferred and the distances involved. A discharge setting of 4-6 seconds will accommodate

about 95% of most pumping jobs with the SV70-SPDK.

Once pumping is completed, remove the suction from the material and allow the pump to cycle self-clean, on completion of the

operations isolate the air supply and allow the pump to cycle until the supply in the line is exhausted, then turn the pump off at the

supply line. SOLIDSVAC recommends checking the pump discharge to ensure it remains correctly anchored at the exit. Lubrication is

not required during operation.

Note: Dry operation will not damage the pump.

CYCLE INDICATOR

Thepumpisttedwithanindicatortoinformtheoperatorwhichcyclethepumpisoperatingin,wheninthedischargecyclethe

indicator is yellow and when in the suction cycle the indicator is clear.

Note: If the pump is supplied with a head of pressure it is possible for the pump to siphon when the air supply is turned off. To

prevent siphoning when the pump is not in operation, turn the pump off when it is in the discharge cycle or isolate the material

supply source to the pump.

DISCHARGE CYCLE INDICATED SUCTION CYCLE INDICATED EARTHING POINT

An earthing point is tted to the

SV70-SPDK if required by the site-

specic RA or JSA.

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page 7

7. MAINTENANCE

In use, the Solidsvac SV70-SPDK requires little to no maintenance, however Solidsvac recommends that the following strict measures

are taken to ensure pump remains in good working order.

Maintenance,repairs,andthedisassemblingoftheunitbecarriedoutbyanyqualiedFitterwithabasicknowledgeofpneumatics.

SERVICE TIPS

- Set up a maintenance schedule and follow it diligently.

- Clean the machine areas before removing pneumatic components.

Note: When steam cleaning or using water to clean a machine, be sure that ller openings, breather caps etc are protected

from possible entry of water into the system.

- Use clean plastic plugs to cover the ends of disconnected lines or to plug openings when working on a pneumatic system.

- A clean workbench is an absolute ‘MUST’ when servicing components. An industrial-type vacuum cleaner is a valuable aid in

removing dust, dirt and tiny metal particles from the work area.

- Check the condition of your tools – they should be clean. Always use hammers made of plastic or leather, so there is no danger

of metal chips getting into components.

- When removing parts for service, clean them and then store them in plastic bags or other clean containers until they are

installed again.

 - Whencleaningpneumaticparts,useextremecaretoensurethatthecleaninguidisnon-ammableandcompatiblewiththe

system.

- Use common-sense precautions to prevent dirt entering components that have been temporarily removed from the circuit.

SYSTEM PERFORMANCE

Pneumaticproblemsthataffectsystemowandpressurearenotalwayseasytolocate.Thesystemtestingproceduredescribedlater

inthissectionisbasedonausefulstep-by-stepapproachtotroubleshooting.Troubleshootingchartsmakethefault-ndingprocess

easier and faster.

EFFECTS OF A DROP IN SYSTEM FLOW RATE

- A pressure drop will affect the speed and cycle times of a pneumatic machine; actuators will not extend, retract, or rotate at

therequiredspeed.Actuatorcontrolwillbecomejerkywithinconsistenciesinowascylindersandmotorsaresuppliedat

different rates. In many complex pneumatic systems, the sequencing and positioning of component operations will be affected

as cycle times become thrown out of programmed control.

 - Thecompressor’sdischargeowrateshouldbecheckedrsttoensurethatthedropinowisnotaproblemofinternal

leakage or incorrect setting of compressor controls.

EFFECTS OF DROPS IN PRESSURE

The major causes of pressure drop include:

 - Pipeworkrestrictions(forexample,incorrectsizing)ttingrestrictionsandsharpcorners

- Incorrect pressure settings

 - Suddenenlargementinuidconductors

 - Longlengthsofuidconductors

 - Componentleakage(internalandexternal)

- Broken valve springs

- Blocked or crimped air lines

 - Loosettings

- Valves not sealing correctly because of contaminants

- Some combination of the above causes

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email [email protected]

page 8

SYSTEM TESTING PROCEDURES

Pneumatic systems, like all machines, require routine maintenance to ensure reliability. However, there are still times when problems

occurandMUSTbelocatedquicklyandefciently,especiallyinproductionapplications.Astep-by-stepmethodhasbeendevisedas

awayofndingandsolvingpneumaticproblemsquickly.

These steps are as follows:

STEP 1: KNOW THE SYSTEM -

Studythemachine’stechnicalspecicationstoobtainanunderstandingofhowthesystemoperatesandthefunctionofthe

machine’s components. Obtain a circuit drawing and check the system through. Check the machine’s maintenance records and

commissioning test results if they are available.

STEP 2: ASK THE OPERATOR -

Determine the symptoms of the problem by asking the operator for a detailed description of the machine’s normal operating

performance.

STEP 3: INSPECT THE MACHINE -

Useyoursenses(touch,smell,sightandhearing)tolocateproblemsordamagesuchasnoisycomponents,airleaks,malfunctioning

components and damaged air lines.

STEP 4: OPERATE THE MACHINE -

Operate the machine and check that the machine’s gauges are reading ‘normal’ and that there are no unusual noises. The operation

of the machine’s controls should not be ‘sticky’ or ‘spongy’. The machine’s performance should not be slow, erratic – nor non-existent.

STEP 5: LIST THE POSSIBLE CAUSES -

Once the fault has been located and recognised, list the possible causes – starting with the simplest.

STEP 6: REACH A CONCLUSION -

Use a troubleshooting chart to check the list of possible causes; then decide which is the most likely.

Note: 99% of all issues are air supply related.

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page 9

SYSTEM MAINTENANCE

A pneumatic system is easy to maintain. However, like any other mechanism, it MUST be operated and maintained correctly.

Pneumaticsystemscanbedamagedbyexcessivepressures,uidcontaminationandbyhighoperatingtemperatures.

Regularmaintenancewillreduceyourpneumatictroubles.Byusingaregularmaintenanceprogramme(preventativemaintenance)

to care for a system, you can eliminate common problems and anticipate special ones. Problems can be corrected or averted before

a breakdown occurs.

The following are the key problems that commonly need to be addressed in pneumatic maintenance:

- Water-contaminated air

 - Poorairltration

- Incorrect pressure settings

- Incorrect lubricator settings, resulting in sticking valves

- High air temperature

- Loose supply lines

- Faulty seals

IMPORTANCE OF CLEANLINESS

Cleanliness is of supreme importance when it comes to servicing pneumatic systems. Keep dirt and other contaminants out of the

system.Smallparticlescanscorevalves,causeseizingofcomponentsandclogorices,resultinginexpensiverepairjobs.

When servicing a pneumatic system, always do the following to ensure cleanliness:

- Keep the compressor and machine's lubricating oil clean

- Keep the system clean

- Keep your work area clean

 - Becarefulwhenyouchangesealorcomponents(takephotos)

- Use caution with compressed air

- Ensure all pneumatic components supply lines are secure

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page 10

AIR INLET FILTER

Prior to commencing each pumping operation:

 - Checkthatallttingsandconnectionareserviceable.

- Adequate compressed air is available.

- A general visual inspection of the unit including the suction and discharge valves

is recommended.

Asmallmetalgauzein-linelterpreventsforeignobjectsenteringtheventurinozzleviatheairsupplyline.

SolidsvacPumpsrecommendperiodicinspectionandcleaningasrequired,replacementltersandsealsareavailablefromyour

Solidsvac suppliers.

EXHAUST BOX

Iftted,SolidsvacPumpsalsorecommendaperiodicvisualinspectionofthe

exhaust box be carried out.

- With the air supply off and isolated, remove the pump cover.

 - Visuallychecktheexhaustopeningandifitappearsblocked,eitherush

the box with a hose, alternatively, remove the 4 cap screws in the side

cover.

- Ensure that there is no foreign material inside the box, remove and clean

the chain and insert back into the box.

- Reinstall the cover and recommence operations.

AIR FILTER

TheSolidsvacSV70-SPDKisttedwithanautodrainltertoreduceforeignmedia

entering via the air supply.

Solidsvacrecommendstheairlterisinspectedregularlyandthelteris

changed as required.

SAFETY FIRST

PRIOR TO COMMENCING ANY WORK ON THE UNIT, THE AIR SUPPLY VALVE MUST BE

ISOLATED AND THE CONTROL SYSTEM TESTED DEAD

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