Conair VRU User manual

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USER GUIDE
UGC062-1016
Non-Reversing Bulk Pump
Assembly
Model VRU – Vacuum Railcar Unloading

It’s a good idea to record the model and serial number(s) of your equipment and the date
you received it in the User Guide. Our service department uses this information, along
with the manual number, to provide help for the specific equipment you installed.
Please keep this User Guide and all manuals, engineering prints, and parts lists together
for documentation of your equipment.
Date:
Manual Number: UGC062-1016
Serial Number(s):
Model Number(s):
DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential
damages in connection with the furnishing, performance or use of this information. Conair makes no warranty
of any kind with regard to this information, including, but not limited to, the implied warranties of merchantability
and fitness for a particular purpose.
Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.
Copyright 2016 l Conair l All rights reserved

Table of Contents I i
Table of Contents
1-1 Introduction
Purpose of the User Guide ............................................................................... 1-2
How the Guide is Organized............................................................................. 1-2
Your Responsibility as a User........................................................................... 1-2
ATTENTION: Read This So No One Gets Hurt .................................................... 1-3
2-1 Description
What is the Non-Reversing Bulk Pump Assembly?........................................... 2-2
How It Works................................................................................................... 2-2
3-1 Installation
Unpacking the Boxes....................................................................................... 3-2
Control Installation .......................................................................................... 3-3
Installing the Non-Reversing Bulk Pump Assembly .......................................... 3-3
4-1 Operation
Starting Operation ........................................................................................... 4-2
Stopping Operation.......................................................................................... 4-3
5-1 Maintenance
Preventative Maintenance Schedule ................................................................ 5-2
6-1 Troubleshooting
Before Beginning............................................................................................. 6-2
A Few Words of Caution................................................................................... 6-2
AAppendix
Customer Service Information ........................................................................ A-1
Warranty Information....................................................................................... A-2

ii I Table of Contents

1
SECTION
1
Introduction
Introduction I 1-1
Introduction
Purpose of the User Guide ..................................... 1-2
How the Guide is Organized ................................... 1-2
Your Responsibility as a User ................................. 1-2
ATTENTION: Read This So No One Gets Hurt.............. 1-3

1-2 I Introduction
Purpose of the User Guide
This user guide describes the Conair Non-reversing Bulk Pump system and explains step-
by-step how to install, operate, maintain and repair this equipment.
Before installing this product, please take a few moments to read the user guide and re-
view the diagrams and safety information in the instruction packet. You should also review
manuals covering associated equipment in your system. This review won’t take long, and
it could save you valuable installation and operating time later.
How the Guide is Organized
Symbols have been used to help organize the User Guide and call your attention to impor-
tant information regarding safe installation and operation.
Symbols within triangles warn of conditions that could be hazardous to users or could
damage equipment. Read and take precautions before proceeding.
Numbers indicate tasks or steps to be performed by the user.
A diamond indicates the equipment’s response to an action performed by the user or a
situation.
An open box marks items in a checklist.
A circle marks items in a list.
Indicates a tip. A tip is used to provide you with a suggestion that will help you with the
maintenance and the operation of this equipment.
Indicates a note. A note is used to provide additional information about the steps you are
following throughout the manual.
Your Responsibility as a User
You must be familiar with all safety procedures concerning installation, operation, and
maintenance of this equipment. Responsible safety procedures include:
•Thorough view of this User Guide, paying particular attention to hazard warnings,
appendices, and related diagrams.
•Thorough review of the equipment itself, with careful attention to voltage sources,
intended use, and warning labels.
•Thorough review of instruction manuals for associated equipment.
•Step-by-step adherence to instructions outlined in this User Guide.
1
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2
0

Introduction I1-3
1
Introduction
ATTENTION:
Read This So No One Gets Hurt
We design equipment with the user’s safety in mind. You can avoid the potential hazards
identified on this machine by following the procedures outlined below and elsewhere in
the User Guide.
WARNING: Improper installation, operation, or servic-
ing may result in equipment damage or personal in-
jury.
This equipment should be installed, adjusted, and serviced by qualified technical
personnel who are familiar with the construction, operation, and potential hazards
of this type of machine.
All wiring, disconnects, and fuses should be installed by qualified electrical
technicians in accordance with electrical codes in your region. Always maintain
a safe ground. Do not operate the equipment at power levels other than what is
specified on the machine serial tag and data plate.

1-4 I Introduction

2
SECTION
2
Description
Description I 2-1
Description
What is the Non-Reversing Bulk Pump Assembly?...... 2-2
How It Works ....................................................... 2-2

2-2 I Description
What is the Non-Reversing Bulk Pump
Assembly?
The Conair Non-reversing Bulk Pump system comes complete with a pump assembly,
4-way valve, and a non-reversing bulk control capible of handling up to four silos or bins.
Through the use of the 4-way valve, a reverse air flow is created for filter cleaning without
the complexity of motor and pump reversal. The control enclosure has complete hook-up
and control facilities for the loading of four different bins and care should be taken during
installation to assure that all connections are in complete accordance with the accompany-
ing wiring diagram.
Specifications
TPCX027-0616 BULK CONVEYING SYSTEMS4VRU 10, 15 AND 25 VACUUM RAILCAR UNLOADING SYSTEMS
www.conairgroup.com |[e-mail] |724 584 5500
C-64
Specifications
How it Works
Dimensions inches {mm} (All Models)
Control Receiver Pump Dust
Collector
Height 25 {635} 45 {1143} 52 {1321} 67{1702}
Width 25 {635} 28 {711} 37 {940} 23 {584}
Depth 8 {203} 28 {711} 62 {1575} 19 {483}
Weight lb{kg} 100 {45} 145 {66} 720 {327} 180 {82}
Model VRU 10 VRU 15 VRU 25
Throughput rates for VRU systems
Throughput with PE 35lb/ft3 *
at 100 ft. 7000 11000 16000
at 500 ft. 3000 5000 8000
Throughput with PET 53lb/ft3 *
at 100 ft. 9000 14000 20000
at 500 ft. 4000 6000 9500
Material / air line size
2.5 in. OD 3 in. OD 4 in. OD
Model VRU 10 VRU 15 VRU 25
Motor Hp 10 15 25
Voltage Amps*
240 30 40 60
480 15 20 30
Power is connected to the main control enclosure. Cable must be provided to
connect the pump motor to the control.
Compressed air requirement
¼ inch NPT to Air Reversal Valve
on Vacuum Pump 60 psi @ 1 CFM
Specification Notes
* In pounds per hour, rates are approximate. Contact a Conair Representative for
guaranteed rates for your application.
Specifications may change without notice. Consult with a Conair representative for
the most current information.
20
16
12
8
6
10
13
17
25
33
100 200 300 400 500
Conveying Rate, lb/hr
(x 1,000)
Hours to Unload a
200,000 lb Railcar
Effective Conveying Distance, ft
PET
@ 53 lb/cu ft
PE
@ 35 lb/cu ft
Typical Conveying Rate/Distance
Performance for VRU 25
Vacuum Cycle to Load Material Pressure Cycle to Power Unload and Clean Filter
Conair offers a complete line of bulk conveying systems for rates
up to 50,000 lb/hr and distances up to 1,000 ft. Conair’s engineers
will evaluate your requirements and offer the system solution that
best fits your needs.

3
SECTION
3
Installation
Installation I 3-1
Installation
Unpacking the Boxes ............................................ 3-2
Control Installation............................................... 3-3
Installing the Non-Reversing Bulk Pump Assembly..... 3-3

3-2 I Installation
Unpacking the Boxes
Upon receiving the shipment, always perform a thorough inspection of the contents and
compare it the enclosed packing list. Make sure all parts listed are present and that no vis-
ible damage exists.
Inspect all of the equipment in the presence of the freight carrier’s representative for dam-
age during shipment. Note any damage on the delivery receipt before signing it. If damage
is evident, file a claim immediately against the carrier as it is their responsibility to pay for
any damage incurred during shipping. Make sure to include a detailed report of the dam-
age along with photos.
Control Installation
Mount control to a wall or other suitable structure where it will be free of vibration and
protected from weather and excessive heat. Operating temperature should not exceed
150°F {65.56°C}.
Run 3 phase electric line of appropriate voltage to disconnect, using wire sizes specified
by local electrical codes. (See wiring diagram for your model’s amperage rating.)

Installation I3-3
3
Installation
Installing the Non-Reversing Bulk Pump
Assembly
Mount pump on a level surface and make sure that the vibration damping pads, which are
shipped with the pump, are installed under the feet. This will help the pump from moving.
Run power wires from the starter output on the motor using appropriate wire sizes. Com-
pliance with NEC and/or local codes is the customer’s responsibility.
Connect the control wire of the pump’s 4-way valve solenoid to terminals 14 and 2 in the
control.
Connect a 60 to 100 psi compressed air source to the 4-way valve assembly.

3-4 I Installation

4
SECTION
4
Operation
Operation I 4-1
Operation
Starting Operation................................................ 4-2
Stopping Operation............................................... 4-3

4-2 I Operation
Starting Operation
Turn on the main disconnect and then turn the selector switch to bin number to be filled.
Turn power switch on.
The pump will start and will load material into the vacuum receiver until the bindicator in
the receiver is satisfied.
The 4-way valve on the pump then reverses the air flow and blows the filter clean. This
backflow of air also aids the discharge of material from the receiver.
After a timed discharge-blowback cycle, the 4-way valve again reverses and material is
loaded in the receiver. This load - unload cycle is repeated until the high level bindicator
in the bin is satisfied. At this time, the pump shuts off and the “bin full” light comes on.
At times, the bindicator in the vacuum receiver may not be satisfied because material
never gets to it. This may be caused by several reasons: A plugged material line; broken
material or vacuum line; the container (railcar, bin, etc.) from which material is being
drawn runs empty. When this happens, the alarm timer lTM will time out and the alarm
light comes on. If the optional alarm horn has been installed, it too will come on at this
time.
If the control switch is in the “shut down” position, the system ill shut down and it will be
necessary to press the reset button to re-start it.
If the control switch is in the “continuous cycle” position, the system will continue to
cycle until it is manually shut down. The alarm light and optional horn will come on and
stay on until the system is shut down or the reset button is pressed.
The ·load timer in the control box should be set 15 to 20 seconds longer than it takes the
material to reach the bindicator in the vacuum receiver. This will prevent frequent nui-
sance tripping of the alarm.
If desired, the bindicator in the vacuum receiver can be omitted. In order for the control to
operate without the bindicator, it is necessary to do the following:
1 Connect jumper to terminals 9 and 13 in control box.
2 Remove relay 3CR (See wiring diagram).
3 Adjust the load timer for necessary. load time.

Operation I4-3
4
Operation
Stopping Operation
1 Turn power switch to OFF.
2 Allow system to cool.

4-4 I Operation

5
SECTION
5
Maintenance
Maintenance I 5-1
Maintenance
Preventative Maintenance Schedule ........................ 5-2

5-2 I Maintenance
Preventative Maintenance Schedule
The Non-reversing Bulk Pump Assembly contains three components that should be veri-
fied for proper operation every six months.
Routine maintenance will ensure optimum operation and performance of the Non-revers-
ing Bulk Pump Assembly. We recommend the following maintenance schedule and tasks.
•Weekly or as often as necessary
rCheck and clean the pump inlet filter.
An inlet filter has been provided to protect the pump from solid material that
can enter and damage the pump impellers. Material can enter the vacuum line if
a loader filter is improperly installed or if it has a hole in it. Replace the pump
inlet filter if it is torn or worn.
rCheck all V/belts.
The V/belts have a tendency to stretch, so an adjustable motor base is provided.
Keep belts tight to prevent slippage and wear. Do not use belt dressings.
•Every 500 hours of operation
rGrease the pump.
Use No. 2 bearing grease or the equivalent. Refer to manuals from the compo-
nent manufacturer for additional information and instructions.
•Every 1500 hours of operation
rChange the oil.
The vacuum pump has been filled with the proper oil and tested by Conair
before shipment. Even so, this oil should be changed periodically. Use SAE 40
regular or an equivalent oil.
•Every three months
rCheck motor bearings and grease, if necessary.
The motor is equipped with double-shielded ball bearings having sufficient
grease to last indefinitely under normal service. But if the motor is used con-
stantly in dirty, wet, or corrosive atmospheres, you should add 1/4 oz. of grease
per bearing every three months. Use a quality, rust-inhibiting, polyure-based
grease such as Chevron SRI. Refer to the motor manual for additional instruc-
tions.
•Every six months
rCheck the vacuum relief valve for proper operation.
The vacuum relief valve is designed to protect the pump from damage if the
conveying line becomes clogged or obstructed.