jurop PN 155R Manual

PN 155
PN 155 R OPERATING AND
MAINTENANCE
INSTRUCTIONS
Authorized Jurop Distributor, Service & Repair Facility
120 – 10293 276 ST, Acheson, Alberta, Canada T7X 6A5
T: 780.962.1827 F: 780.962.1830 E: [e-mail]
www.fraserwoods.ca

INDEX
1. INTRODUCTION
2. DIMENSIONS
3. FEATURES
4. NORMAL USE
5. USAGE LIMITATIONS
6. PERFORMANCES
7. SAFETY AND ACCIDENTS PREVENTION
8. INSTALLATION
Checking upon receipt Mounting
Vacuum – pressure line
9. DRIVE
Cardan shaft drive
Belt drive
Hydraulic drive
Precautions when starting the system
10. OPERATING PRECAUTIONS
11. ORDINARY MAINTENANCE
Checking the drip oilers
Checking the side mounted tank oil level
Checking the vanes wear
Checking the gear box oil level
12. EXTRAORDINARY MAINTENANCE
Adjusting the 4-way valve
Replacing the vanes
Adjusting the self-lubricating pump
13. TROUBLESHOOTING
14. SCRAPPING
15. SPARE PARTS REQUEST
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This booklet contains the necessary instructions for a
correct installation, starting-up, running, and
maintenance of the vacuum pump as well as some
practical basic rules for a safe operating.
The knowledge of the following contents will grant a
long and trouble-free operation of the pump. The
observance of these operating and maintaining
instructions is absolutely necessary to have the
guarantee for defective parts acknowledged.
The manufacturer shall not be deemed responsible for
any damages resulting from an improper, incorrect or
unreasonable use of the pump.
It is therefore strictly recommended:
•the operators be acquainted with these
instructions;
•the booklet be kept in a place at hand known by all
users.
In these instructions, some graphic symbols are used to
draw the attention to some particular operations:
If these safety rules are not respected,
operators can be injured and the pump or
oilers damaged remarkably.
If these safety rules are not respected, the
pump or system can be damaged.
Suggestions for an environment-friendly
use of the pump.
Useful information for an easy usage and
maintenance of the pump.
PN155 D left splined shaft (A350709410)
PN155 D smooth shaft, L rotation (A350909410) PN155 D smooth shaft, R rotation (A350809410)
PN155R D left splined shaft (A360709410)
PN155R D smooth shaft, L rotation (A360909410) PN155R D smooth shaft, R rotation (A360809410)
2. DIMENSIONS PN155
–
PN155 R
1. INTRODUCTION
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PN155 M 540 rpm, left rotation (A353209410) PN155 M 1000 rpm, left rotation (A353509410)
PN155R M 540 rpm, left rotation (A363209410) PN155R M 1000 rpm, left rotation (A363509410)
PN155 HDR, right rotation (E3508109410) PN155R HDR, right rotation (E3608109410)
HDR MOTOR FEEDING
Motor Displacement
cc/rev. Operating Pressure bar Max. Flow l/min
86 140 100
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PN155 FL 540 rpm, left rotation (A353219410)
NOTE. The vacuum pump PN155 may be equipped with aluminium conveyors.
Kit fixed conveyor Ø100 with valve connection: cod. 18521 035 00
Kit swivelling conveyor Ø100: cod. 18521 040 00 Kit valve connection: cod. 18521 041 00
•Rotary vacuum pump with radial vanes and
air cooling system.
•Automatic lubrication with volumetric pump
and side mounted tank.
•Built-in vacuum-pressure change-over valve.
•Non return valve (rubber ball) inside pump
manifold.
•Aluminium conveyors.
•Gear box drive (splined shaft ASAE 1 3/8) 540
rpm or 1000 rpm, left rotation.
•Direct drive with smooth shaft, right or left
rotation.
•Direct drive with splined shaft ASAE 1 3/8, left
rotation.
•Hydraulic drive with gear motor, right rotation.
As model PN155. In addition:
•Extra air injection cooling system.
•High resistant vanes.
OTHER FEATURES ON REQUEST:
•Rotation other than the standard one.
•Pneumatic or hydraulic actuator for the 4-way
valve.
The vacuum pump PN155 is designed to convey filtered air into systems for the vacuum production or for the
suction of powders or liquid wastes. Any other usage shall be considered improper.
Do not sack toxic substances and inflammable or explosive gasses, since the internal components of the
pump may reach high temperatures.
Liquids or solids infiltrations can seriously damage the pump
Do not run the pump over its designed operating limits (see “Usage limitations): it may break and
transmission can be damaged.
3.2 FEATURES PN155R
4. NORMAL USE
3.1 FEATURES PN155
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MAX. SPEED – OPERATING SPEED (RPM) P2
(bar ABS) T2
(°C) T2- T1 (°C)
PN155 – PN155R
M - 540 PN155 – PN155R M - 1000 PN155 D / PN155R D PN155 HDR / PN155R HDR Max Max Max
540 - 470 1000 - 900 1150 - 1000 2 * 150°C 130
P1: absolute pressure during suction T1: temperature during suction
P2: absolute pressure during delivery T2: temperature during delivery
NOTE. *Belt drive only for PN155 D and PN155R D: P2= 1,5 abs bars.
Air flow (free air
condition) l/min 15200
Vacuum at continuous
duty
PN155 60 %
Air flow at 60% vac. l/min 13500 PN155 R 70 %
Max. vacuum % 93 Oil consumption g/h 250
Power required at max.
vacuum kW 19 Sound pressure level ** dB (A) 79
Power required at 2 abs
bars pressure kW 23 Weight kg 220
**: only when decompressor at max. speed, 60% vacuum rate, 7 m distance in open field.
Performances referred to decompressor operating at max. speed.
REFERENCE CONDITIONS:
Conveyed gas: air Functioning in free air.
Reference abs. pressure: 1.013 mbar Reference temperature: 20°C
Vacuum functioning: free outlet Pressure functioning: free inlet
CAREFULLY OBSERVE THE FOLLOWING RULES
•When transporting the pump, use proper slinging. Store the pump in stable places.
•Installation and maintenance must be operated only by qualified personnel wearing the proper clothes
and the necessary tools as well as protection devices.
•Before each maintenance operation:
•Stop the pump and restore the atmospheric pressure.
•Disengage the drive system.
•Only operate after the pump has cooled down.
•When the pump is running, some parts may reach very high temperatures (above 100°C). Use all
necessary precautions to avoid contact.
•Operators working nearby must avoid prolonged exposure to the noise emitted by the aspirator, if not
equipped with the proper ear-protection devices.
•Avoid accidental suction of solids: solids may be projected at high speed through the exhaust manifold
and cause injures.
7. SAFETY AND ACCIDENTS PREVENTION
6. PERFORMANCES
5. USAGE LIMITATIONS
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•Do not start the machine if the protection devices provided for transmissions are removed. Replace
damaged parts.
•Pressure relief valve: point the air flux away from the operators.
•Do not use the aspirator over its designed limits: the machine may be damage and the operator may
be injured.
Dispose of exhausted oil (accumulated in the silencer’s separator at the exhaust) and the oil used in
the vacuum pump maintenance (internal wash-up or periodical replacement in the gear box) as
provided by current specifications.
Legend of main components:
A. Multiplier gear box
B. Manifold
C. Vacuum – pressure manifold
D. Non return valve
E. Vacuum relief valve connection
F. Oil tank
G. Oilers
H. Lubrication pump
I. Air injection valve
J. Swivelling conveyor
K. Conveyor with safety valve connection
L1. Tank oil stand
L2. Gear box oil stand
8. INSTALLATION
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CHECKING UPON RECEIPT
•When the goods are delivered, make sure that all parts listed on the delivery note are in perfect
condition and have suffered no damage during shipping.
•Make sure the vacuum pump has its identification plate affixed on the front cover. Pumps without such
identification are to be considered anonymous and potentially dangerous: in such an event, they must
not be used, otherwise the manufacturer will be deemed free from any liability whatsoever.
MOUNTING
•The pump must be assembled for an easy access for maintenance operations and secured rigidly to a
frame or levelled base (max. 5° slant to the horizontal plane). The base must be such as to avoid
vibrations, bending or deformation.
•The oil tank is mounted on the suction side of the unit. Thus, the rotation direction determines the pump
overall dimensions. See par. “Dimensions”.
•Make sure there is enough room around the pump for the air for the cooling system to freely circulate and
avoid exposure to dirt and debris.
Prepare enough room for an easy access to:
1. Vanes wear check port
2. Oilers
3. Oil tank level
4. Oil tank inlet plug
5. Oil tank outlet plug
6. Self-lubricating pump
7. Gear box oil level
8. Gear box oil outlet plug
9. Gear box oil inlet plug
10. 4-way valve handle
2 VACUUM – PRESSURE LINE
•In order to avoid accidental suction of liquids inside the pump, install a primary (pos. 1)
and a secondary flow shutoffs (pos. 2). If necessary, install also a suction filter (pos. 3) to protect
from solids infiltration.
•The exhaust silencer is designed to reduce the noise level and to separate the oil mist coming out
from the pump outlet port. The separator must be periodically drained from oil and condensate
accumulated in the separator during the normal pump functioning.
•The diameter of the vacuum/pressure line pipes must be properly dimensioned to the pump flow
and, in any case, larger than the diameter of the ports (Ø100 is recommended).
•The pipes weight must not solicit the body of the pump. Use high temperature resistant rubber
connections.
•Before mounting the vacuum line to the pump, remove the port protections. Pipes and all line
components must be clean.
•Avoid restrictions and tight curves as much as possible if not strictly necessary.
•Exhaust pipes can reach high temperatures. Hence, they must be properly isolated.
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•Max. pressure safety valve on delivery: mount it close to the pump. The valve flow must prevent
the PN155 from exceeding the absolute operating pressure (see par. “Usage limitations”) or, in
any case, the maximum pressure allowed by the system. Do not apply gate valves on the line.
•Over-pressure safety relief valve (pos. 6): to apply if necessary to limit the vacuum rate in the
system.
Pos Description
1 Primary flow shutoff
valve
2 Secondary shutoff
3 Suction filter
4 Exhaust silencer with oil
separator
5 * Over-pressure safety
relief valve
6 * Vacuum relief valve
* : optional components
CARDAN SHAFT DRIVE
Use telescopic cardan shafts. In order to achieve a uniform
motion of the driven shaft, the following requirements must
be met:
•Equal working angle αand α1 of both couplings.
•The internal fork joints must be coplanar.
•Both driven and driving shafts must be coplanar.
It is also recommended working with limited articulated joint
angles (max. 15°) and disengaging the transmission for
those operations requiring great angles (steering or lifting).
Follow the rotation direction as indicated on the
front flange. Follow the instructions of the cardan
shaft’s manufacturer.
Use the cardan protection supplied with the pump.
The pump installation must fulfil the current EC
injury prevention specifications.
8. DRIVE
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BELT DRIVE
•Install a suitable pulley on the smooth shaft as close as possible to the pump: max 35 mm.
•Apply an adequate belt tension (see manufacturer’s data). Max 3000N.
•Do not use driven or driving pulleys with a pitch diameter inferior to 180 mm. Small pulleys
require a high belt tension which may cause premature wear to the bearing or transmission
troubleshooting
NOTE
If the pump PN155 is run through a belt drive, its working pressure must not exceed 1.5 abs.
bars to prevent it from absorbing a power requiring an excessive belt tension. There is no limit
to the operation in vacuum.
Drive min. pulley
pitch diam. Belts Max. Speed Max. Pressure Max. Vacuum
mm rpm bar abs %
180 XPB x 3 1150 1,5 93
HYDRAULIC DRIVE
•Motor features
Displacement Max. operating pressure Max pressure draining line Max. press. motor exhaust
cc/rev bar bar bar
86 220 5 5
•Fluid: mineral oil for hydraulic systems in compliance with ISO/DIN
Temperature Optimum viscosity Max. viscosity allowed
°C cSt cSt
-20 / +80 12 - 100 750
MAX
3300 N
35 MAX
KEEP AXELS PARALLEL
ALIGN PULLEY GROVES AND
BELTS
CHECK BELT TENSION
D
p
= 180 MI
N
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•Filtration: class 19/16 contamination according to ISO 4406
to be obtained with a ßx = 75 filter
•Check circuit connections: they must be applied in the same
rotation direction as that indicated by the arrow on the pump front
flange.
•Draining: connect directly to the tank above the maximum oil
level. Operating without draining line may damage the motor.
Pos Description
1 Hdr pump
2 Distributor
3 Hdr motor
4 Oil filter
5 * Heat exchanger
6 * Safety valve
* : optional components
•Distributor: open-centre distributor in central idle position (vacuum pump off). It must be
equipped with an adjustable overpressure safety valve.
•Motor pipeline: outlet pipe must not be of a smaller diameter than that of the inlet port. Inlet pipes
always have a diameter smaller than outlet pipes. Choose preferably flexible pipes to avoid
vibration transmission.
•Tank: with suction pipe and return separated by baffles. If necessary, use a heat exchanger to
avoid oil heating above 70-80°C and protect it from extreme pressure with a pressure relief valve.
Minimum approximate capacity: as twice as the circulation flow.
•Starting-up: be sure that the system is well cleaned and pour oil into the tank and into the motor
housing (necessary to lubricate the internal bearings).
•Vent the circuit and adjust the overpressure safety valve to the lowest possible value.
•Check the oil tank level.
•Increase pressure and rotation speed until operating values are reached.
PRECAUTIONS WHEN STARTING THE SYSTEM
Check oil levels in gearbox and side mounted tank.
Check that all protection devices are correctly installed.
Check that there are no obstacles in the vacuum line.
Check rotation direction: open all system valves and start running slowly.
Do not rotate in the wrong direction: this may damage the vacuum pump. Follow the arrow
indicated on the front flange.
DRAINING
PORT
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Check which position of the four-way integrated valve lever allows vacuum or pressure functioning.
Close the valve and increase vacuum rate (or operating pressure).
Check that the lubricating pump works properly. Oil must regularly drip into the oilers. Typically 35 drops/min
(at maximum speed).
Check loading and operating speed for vibrations or unusual noises.
This vacuum pump is designed to work at maximum speed, but for longer operating we
recommend the pump be run at working speed (see par. “Usage limitations”). Adequately
prepare the transmission.
•Do not make the vacuum pump overheat: maximum air temperature on exhaust (or delivery) side:
150°C.
•Do not operate the pump without lubrication: it may cause quick wear and possible breakdown of
vanes.
•Do not start running the pump under load: this may damage the drive system or the hydraulic motor.
•Check the rotation speed: it must never exceed the operating limits indicated on the identification plate
of the vacuum pump.
•Do not accidentally operate the pump in the wrong direction: it may break the vanes.
•Do not convey the exceeding delivery outlet towards the suction port, otherwise it will sack warm gas.
•Control the air flow by adjusting the rotation speed: do not use the pressure relief valve to discharge
the exceeding flow.
•Internal wash-up is necessary after prolonged inactivity, after working in dusty environments or in
case of accidental suction of liquids. Such operation must be carried out only on cooled pumps.
•Disconnect the exhaust silencer, if possible.
•Start running the pump at low speed.
•Suck some water (about 1-2 litres) through the inlet port.
•Then suck oil (about 1 litre) to complete the wash-up and lubricate internal components.
In case the exhaust line cannot be disconnected, drain the liquids accumulated in the separator of
the exhaust silencer.
ROTATION SPEED.
Once the needed vacuum rate has been reached, we recommend reducing the vacuum pump
speed to its working speed (see paragraph “Usage limitations”): this allows keeping the
achieved vacuum/pressure rate constant. The pump speed can also be reduced to values lower than the
working speed during the tank discharging phase (with the 4-way valve in pressure mode) without
increasing the draining time. Thus, exhaust temperature is reduced, vane durability is increased and
both oil consumption and power absorption are reduced.
WARNING
WARNING
10. OPERATING PRECAUTIONS
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Before starting any maintenance operation, follow the safety prescriptions as described in
paragraph “Safety and accidents prevention”.
PUMP OPERATION
CONDITION CHECKING FREQUENCY
OPERATING
Lubrication: dripping into oilers D
Rotating speed D
Working pressure D
STANDSTILL
Side mounted tank oil level D
Clean filter and vacuum line shutoff.
Drain the oil gathered in the exhaust separator. D
Check vanes wear W
Check pressure relief valve condition M
Gear box oil level M
Gear box oil change 1500 h
Frequency: D: daily W: weekly M: monthly
CHECKING THE DRIP OILERS
Check dripping into the oilers.
Be sure it is regular (app. 35 drops/min at max. speed) to grant a correct lubrication of the pump. At
lower speeds, the number of drops must be directly proportional.
CHECKING THE SIDE MOUNTED OIL TANK LEVEL
Do not run the pump with oil level under the minimum level: that may lead to dry functioning and cause
serious damages. Tank capacity: 4 litres. Use pure fresh oil.
Do not re-use the exhausted oil gathered on the bottom of the exhaust silencer.
Recommended lubricants
Room.
Temp. Viscosity Type AGIP ESSO SHELL ELF MOBIL BP
Below
10°C ISO VG 46 Mineral oil RADULA 46 NURAY 46 VITREA 46 MOVIXA 46 RUBREX 300 ENERGOL CS 46
Above
10°C ISO VG 150 Mineral oil RADULA 150 NURAY 150 VITREA 150 MOVIXA 150 RUBREX 900 ENERGOL CS 150
11. ORDINARY MAINTENANCE
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CHECKING THE VANES WEAR
•Unscrew the vanes wear check-plug on the housing.
•Turn the shaft until you see the vane.
•The vanes should slide to the bottom of the seat due to
gravity: check they really do.
Replace the vanes when their wear exceeds 10
mm (L – L min): they may break. Replace all
vanes at the same time.
CHECKING THE GEAR BOX OIL LEVEL
Check the level when the pump is cooled: it must almost reach
the threaded port. Refill if necessary.
For a complete replacement, 0.7 litres are required. Use mineral
oil with EP additives for gears and transmissions.
Recommended lubricants
Viscosity Type AGIP ESSO SHELL ELF MOBIL BP
ISO
VG 220 EP mineral oil BLASIA 220 SPARTAN EP 220 OMALA OIL 220 REDUCTELF SP 220 MOBILGEAR 630 ENERGOL GR XP 220
Dispose of exhausted oil as provided by current specification.
When changing the oil, also replace the outlet plug washer.
Before starting any extraordinary maintenance operation, be sure the pump stands still and
follow the safety prescriptions as described in paragraph “Safety and accidents prevention”.
ADJUSTING THE 4-WAY VALVE
For pumps equipped with handle for manual
operation or hydraulic actuator.
Adjust the screws to avoid the valve blocking
in its seat.
Do not exceed with the adjustment:
possible vacuum loss.
For pumps equipped with changeover valve
with hydraulic actuator: see the integrated
part at the end of these instructions.
12. EXTRAORDINARY MAINTENANCE
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REPLACING THE VANES
•Remove the vacuum pump from its bearing frame and wash it before disassembling.
•Disconnect the lubricating piping. Remove the screws fixing the rear flange and use the two
threaded holes to remove the flange – bearing – seal housing. If necessary, hold the rotor by
inserting a wooden block, protecting the internal bearings from damage.
•Remove the bearing from the rear flange and replace the seal if damaged.
•Lubricate with oil the new vanes before inserting them inside each groove of the rotor.
•Reinstall all components in the following order: rear flange, seal ring (non), bearing, compensation
ring, gasket and flange with lubricating pump (we recommend the pivot-key be correctly fitted onto
the shaft groove).
WARNING
Do not damage
components during
assembly by forcing them
exceedingly. Do not flip the
seal ring during rotation of the
shaft. Do not leave foreign
objects inside the pump.
ADJUSTING THE SELF-LUBRICATING PUMP
The automatic lubricating pump is adjusted by the manufacturer
before the shipping. If consumption noticeably differs from the
indicated value, adjust it as follows:
•Remove the upper protection cover.
•Using a screwdriver and a 10 mm wrench, adjust the adjusting
screw (K). Close the nut and remount the upper protection
cover. It is advisable to turn the screw of ¼ of turn and verify
the actual consumption.
•We recommend turning the adjusting screw by a ¼ turn and
then check the actual vacuum pump consumption.
Do not reduce oil consumption below the value indicated in par.
“Performances” (for functioning at speeds different from the
maximum, flow is proportionate to rotating speed).
½ turn of the adjusting screw causes a variation in the flow
of appr. 40 - 80 g/h, depending on using conditions.
-+
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The vacuum pump overheats
Insufficient or absent lubrication Verify oil and rings. Check oil pump efficiency
Low tank oil level Fill tank with oil
Excessive rotation speed Reduce rpm to the prescribed working speed
Prolonged functioning at max vacuum rate Reduce vacuum rate
Vacuum and/or exhaust line of insufficient diameter Check dimensioning
The vacuum pump does not rotate
Broken vanes: Clean inner chambers, replace vanes
- due to infiltrated solids Check the secondary shutoff and filters of the
suction line
- due to insufficient lubrication Check the oil pump
Power transmission breakdown Check and replace the damaged parts
Ice inside the pump (during the cold season) Remove ice and slowly start running it. Avoid
suction of water.
Reduced performances
Four way changeover valve in idle position Move the lever to vacuum or pressure mode end
stroke.
Four way changeover valve not correctly registered Adjust the functioning play and lubricate
Worn vanes Replace vanes
The non-return valve leaks Clean or replace if necessary
Worn seal rings Replace
Tank gate valves or gaskets leak Replace damaged or worn parts
Tank connection pipes leak or are obstructed Replace damaged pipes
Obstructed primary shutoff or suction filter Remove and clean
Encrusted exhaust port Remove and clean
Vacuum line components are too small dimensioned Verify dimensions for pump maximum performances
Obstructed rubber couplings Replace
Unusual oil consumption
Insufficient or absent lubrication Check and adjust the lubricating pump
13. TROUBLESHOOTING
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Before dismantling, the followingcomponents must be properly disassembled and divided:
•Lubricating oil
•Rubber and plastic parts
•Cast iron, steel and aluminium parts
Do not leave in the environment.Do not use dismantled parts as spare parts
To order spare parts, give the following information
Find in the parts list:
•code
•name
•quantity
(Ex. : cod. 1601606200 ; Vane; 4 pz
Find on the suction plate:
•model
•serial number
(Es. : LC 420 ; H60013
14. SCRAPPING
15. SPARES PARTS
REQUETING SPARE PARTS
Authorized Jurop Distributor, Service & Repair Facility
120 – 10293 276 ST, Acheson, Alberta, Canada T7X 6A5
T: 780.962.1827 F: 780.962.1830 E: [e-mail]
www.fraserwoods.ca