PIAB C Series User manual

VACUUM CONVEYING
C Series Conveyor
Troubleshooting Guide
www.piab.com

VACUUM CONVEYORS
2
INTRODUCTION
Thank you for your purchase of a
PIAB Vacuum Conveyor.
This manual provides you all the information
necessary for the successful installation, op-
eration and maintenance of your unit. We
strongly recommend that this manual be
carefully studied prior to installation or opera-
tion. Doing so will avoid the possibility of in-
advertent damage or malfunction of the
equipment. Following the recommended
maintenance instructions will ensure better
performance and extended equipment life.
Also included within this manual is a list of
recommended spares. These items are sub-
ject to wear during normal use. We recom-
mend that they be purchased in advance and
keptinstocktoavoid possible down time and
future delays.
Because PIAB equipment may be shipped as
part of an installation involving other types of
equipment, or dissimilar units are sometimes
connected to perform specific functions, you
should familiarize yourself with the manuals
covering the other equipment before pro-
ceeding with installation. By cross-referenc-
ing the manuals, you may save valuable in-
stallation time and avoid improper operation.
In the design and manufacture of this equip-
ment, PIAB has exercised the utmost care to
ensure many years of trouble-free operation.
Intheeventthatpartsortechnicalassistance
is required, please contact us at:
PIAB USA, Inc.
65 Sharp Street
Hingham, MA 02043
Ph: [phone]/ [phone]
Fax: [phone]
[email protected]
www.piab.com
It is the users' responsibility to operate this
equipmentina safe mannerandensurecom-
pliance with all applicable safety laws and
codes.
WARRANTY:
PIAB Vacuum Conveyors are thoroughly in-
spected and tested before shipping. Each
PIAB Vacuum Conveyor is warranted to be
free of defects in workmanship and materials
forfiveyears fromdateof purchase(filterand
wear parts excluded.)

VACUUM CONVEYORS
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CONTENTS
Page
SAFETY INSTRUCTIONS 4
CONNECTION EXAMPLES 7
CU-1A/B Connection
CU-2A/B Connection
PPT/R Connection
VCC-EP Connection
ACHIEVING THE DESIRED RATE 16
Filter replacement
Cleaning and Maintaining the Pump
MLL200-1200 Components
MLL Panel Component
Inside Components of MLL Pumps
MLD100 Components
TROUBLESHOOTING GENERAL 24
TROUBLESHOOTING L SERIES PUMP 25
TROUBLESHOOTING CU-1A/B 33
PIAB Control Unit CU-1A/B & CU-2A/B
CU control function and pneumatic diagrams
/ Pipe emptying
TROUBLESHOOTING PPT/R 42
PIAB Control Unit PPT/R
PPT/R control function and pneumatic
diagram, connections
Disassembling a PPT/R control
TROUBLESHOOTING VCC-EP 48
PIAB Control Unit VCC-EP
Mounting and connections
Valve Connections for the VCC-EP
TROUBLESHOOTING WITH
A LEVEL DETECTOR 51
PIAB Level Detector
TROUBLESHOOTING INJECTION VALVES 51
Pneumatic Injection Valve
CLEANING OUT A PACKED CONVEYOR 54
Air Shock Assembly
MAINTENANCE SCHEDULE 55

VACUUM CONVEYORS
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SAFETY INSTRUCTION
Instructions for building into a system
PIAB vacuum conveyors are CE marked. The person
who installs the conveyor in another main system has
the responsibility of carrying out a risk analysis when
this is desired.
Dust explosions
When handling and conveying dry powders and mate-
rial consisting of small particles, there is a risk that a
dust explosion may occur. A dust explosion may occur
whencertainfinelydivided materialsare mixedwith air
(oxygen) and then are ignited by, for example, a spark.
In order to minimise the risk of dust explosions, all in-
cludedpartsoftheconveying systemmustbe connect-
ed to one and the same point of earth (equipotential)
accordingto applicableregulations.Itisalsoimportant
not to smoke, weld or carry out other work where the
risk of generation of sparks may be present in the vi-
cinity of the conveyor.
Inthetablebelowaresomeexamplesofmaterialsthat
may cause dust explosions.
The conveyor may not be used in explosive surround-
ings containing the following gases: acetylene, carbon
disulphide, hydrogen, hydrogen sulphide and ethylene
oxide.
ATEX-Atmosphere Explosible and CE.
PIAB vacuum conveyors are not EX classified.
PIAB vacuum conveyors conforms to EU directive 94/
9/EC.
Cleaning of filters
Itisimportant tocheckand clean/changefiltersatreg-
ular intervals so that they are not clogged, as this
might lead to the fact that the filters will be subjected
to overload, and that undesired matters or particles
leak from the conveyor.
Emergency stop
The system builder shall provide the machine with an
emergency stop function. As an option to the vacuum
conveyor there is a remote control box with a built-in
emergency stop function.
Start/stop of the conveyor
Theconveyorisstartedeitherwiththeprovided control
unit or via another main control system. The conveyor
stops if the supply of compressed air is suddenly inter-
rupted. The conveyor must be re-started by the opera-
tor even if the supply of compressed air is reactivated.
Vacuum power at the inlet
Careless usage and incorrect installation of the feed-
ing point of the vacuum system may cause injuries.
The vacuum level is concentrated at the feeding point
and may cause injuries to eyes and mucous mem-
branes.
XNeveraimasuctiontube,a feednozzleor a hose
at anyone.
XThe larger the suction inlet, the higher the power
and danger.
XThe installation must be made so that the inlet
cannot contact the operator and other people.
XAlways remember to disconnect the supply of
compressed air when cleaning or servicing the
vacuum conveyor.
X
Aluminium Carbon
Aspirin Magnesium
Cotton Flour
Iron Nylon
Cacao Sugar
Coffee Corn
Cork Wood
+O2+=

VACUUM CONVEYORS
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Exhaust from the vacuum pump
The exhaust air from the conveyor’s vacuum pump
may, in certain applications, constitute a risk and
cause injuries. If the filter is not fully intact when pow-
der with small particles is conveyed, the particles may
penetratethefilterand enter the pump, andfurtheron
out to the atmosphere and possibly contaminate it.
Dangerous gases may also be generated and be car-
ried out together with the exhaust air. In such cases
the pump shall be fitted with a central exhaust with an
external filter. In certain cases, another alternative
could be the use of a sterile-filter unit. Never look di-
rectly into the outlet of the vacuum pump. Do not for-
get to disconnect the supply of compressed air when
cleaning or servicing the vacuum conveyor
Compressed air
We recommend that compressed air of at least quality
class 3 is used (ISO norm 8573.1) for PIAB’s vacuum
pumps. This means that only a maximum of 5 mg/m3
of a maximum of 5 µ size particles may be present in
the compressed air.
For the USDA conveyor to conform to the American re-
quirements of the authorities, the air for the air shock
must be delivered according to 3-A Accepted Practice
No. 604-04. This means, among other things, that the
air shall be free from oil and be filtered.
Preventing pressure-drops in
the air supply
It is important to correctly dimension the compressed-
air hose that supplies the conveyor so that unneces-
sary pressure drops do not occur. The longer the hose,
the larger the dimension required. Also remember
thatpush-inconnections with built-innon-returnvalves
may cause pressure drops. Also, take into consider-
ation that there may be other devices in the com-
pressed-air network that might consume compressed
air.
Dimensioning of the compressed-air pipeline
A very important part of a vacuum system is correctly
dimensioned hoses and connections. In order to get
the highest possible performance from each vacuum
pump, the table below that recommends hose diame-
ters in mm (inner diameter) should be used.
The above compressed-air connections apply for pipe-
lines that are shorter than 10 m (33 ft). If the pipeline
is longer than 10 m (33 ft), select a pipeline of a larger
diameter.
Installation of compressed air
The feed pressure of the compressed air is between
0.4(58)and0.6 (87 psi) MPaforPIABvacuum convey-
orsandpumps.Careless usage ofcompressedairmay
cause injuries.
The compressed air may not be used for any other pur-
pose than specified.
All applicable safety regulations for installation, opera-
tion and maintenance must be followed.
Always disconnect the supply of compressed air when
cleaning or servicing the vacuum conveyor.
You are responsible for your own and other people’s
safety at the place of work.
Contact your local PIAB distributor if you have any
questions.
Pump model Compressed-air
connection
Exhaust connec-
tion (mm)
Maxi L100 1/2" 75
Maxi L200 1/2" 75
Maxi L400 1/2" 75
Maxi L600 1" 2x75
Maxi L800 1" 2x75
Maxi L1200 1" 2x75
Maxi L1600 1" 2x75

VACUUM CONVEYORS
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Disconnecting the compressed-air pipeline
Before the compressed-air pipe of the pump is discon-
nectedthepressuretothecompressor mustbeturned
off. After that, the pipeline may be disconnected.
Dismounting the conveyor
It important that the conveyor is emptied of its powder
before dismounting is started. The compressed-air
supply must be disconnected before dismounting the
conveyor.
Mounting of the conveyor
The conveyor is delivered mounted. When mounting it
after cleaning/servicing, it is important that seals and
filters are mounted correctly so that leakage does not
occur. C21 and C33 shall be anchored at one point at
least (either at the bottom valve unit or at the connec-
tion girdle). C56 shall be anchored at two points at
least (at the bottom valve unit and at the upper or low-
er connection bracket).
Hot surfaces
There is a risk that the external air shock becomes hot
(60° C, 140° F) during and after use.
Position of the operator
The operator shall be at a position where he can easily
start and stop the conveyor.
Remote control of the conveyor
When using remote control, the system builder should
ensure that the conveyor can not be simultaneously
operated from two locations.
Installation of the conveying pipeline
Correctdimensioning andinstallation isAandOforthe
system to work in the best possible way.
Please contact your local PIAB distributor as to dimen-
sioning of the diameters of the pipes, their length,
number of bends and possible option of injection units
or pipe emptying function. It is important that the pipe-
line system is sealed in order to prevent the conveyed
powder from leaking from the equipment to cause
damage to other devices and injuries. It is also impor-
tanttomakesurethatno foreignmatterscaninadvert-
ently be sucked into the conveyor.
Some basic tips
XThe conveying pipeline should be installed without
having any unnecessary bends.
XAvoid inclined rises in the conveying pipeline.
XThe radius of the pipeline should be at least 10
times the pipe diameter.
XChoose pipes instead of hoses where possible.
XAvoid all types of edges and restrictions at pipe
joints and connections.
Noise level
The measured noise levels (72–76 dBa) have been
measured in the following manner. The distance be-
tween the pump and sound level meter = 1 metre. The
higher measuring value applies to the exhaust air-flow
in the direction of the sound level meter and the lower
measuring value applies to the exhaust air flowing
from the sound level meter. Please notice that the
noise level of the conveying depends on the kind of
powder that is conveyed.

VACUUM CONVEYORS
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CONNECTION EXAMPLES
CONTROL UNIT CU-1A/B ART. NO. 01 04 550
ART. NO. 01 04 552

VACUUM CONVEYORS
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CONTROL UNIT CU-1A/B WITH FLUIDISATION ART. NO. 01 04 550
ART. NO. 01 04 552

VACUUM CONVEYORS
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CONTROL UNIT CU-1A/B WITH FLUIDISATION AND LEVEL DETECTOR ART. NO. 01 04 550
ART. NO. 01 04 552

VACUUM CONVEYORS
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CONTROL UNIT CU-1A/B USDA ART. NO. 01 04 550
ART. NO. 01 04 552