RoboVent FlexPro Hi-Vacuum Series System manual

©2020 ROBOVENT PRODUCT GROUP, INC.
OWNER'S MANUAL & OPERATING INSTRUCTIONS
Original Instructions
Manufactured by: RoboVent Product Group, Inc., 37900 Mound Rd., Sterling Heights, MI 48310, USA | (888) ROBOVENT | www. robovent.com
OWNER'S MANUAL & OPERATING INSTRUCTIONS
Original Instructions
FlexPro Hi-Vacuum Series Cartridge Collector
Model Number: HVE-175-80-1
for Serial No. 27310 and higher

FlexPro Hi-Vacuum Owner's Manual & Operating Instructions
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Table of Contents
Introduction 3-5
Receiving & Inspection 3
Safety Signs & Symbols 3
Purpose & Limitations 3-4
Prerequisites for Use 5
Specifications 6-9
Specification Chart 6
Data Plate Info 6
Dimensions 7
Airflow Schematic 8
Components 9
Unpacking & Locating 10
Environmental Requirements & Constraints 10
Process for Locating 10
Testing & Commissioning 11
Installation 12
Operating Instructions 13
ePad Operating Instructions 14-18
Preventative Maintenance 19
Replacement Parts 20
Troubleshooting 21
Wiring Diagrams 22-28
OSHA's Hexavalent Chromium Standards 29-30

FlexPro Hi-Vacuum Owner's Manual & Operating Instructions
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Introduction
Thank you for choosing the RoboVent HVE Hi-Vac filtration machine. This high-
vacuum unit is designed for industrial environments, collecting both fumes
and dust at the source in welding and related processes. The energy-eicient
motor is directly coupled to the regenerative blower and operated by onboard
controls, combining what might otherwise be a very complex operation into a
simple, user-friendly package. It ships in two pieces, the motor/filter cabinet
and the dust containment (hopper) and is pre-tested, making it easy to set up
and use.
The HVE Hi-Vac machine has been designed for production use and has a few
standout characteristics:
Regenerative blower: The backbone of the machine, it requires little
maintenance, and the advanced design provides the powerful suction required.
Vertical cartridge filters: Vertical cartridge filters have superior loading and
cleaning performance; RoboVent Endurex filters improve on these inherent
characteristics with proprietary design features that optimize performance and
promote eective pulse cleaning.
Pulsing system: Automatic and eicient, the pulse system ensures filter life is
maximized. Online and oline modes work together as needed to ensure filter
is consistently cleaned: a quick pulse sheds dust from the filter, causing it to
fall into the hopper area and collect in the drum. Eective pulsing is combined
with a filter chamber designed to prevent re-entrainment of dust, resulting in
maximum filter life.
Intuitive controls: Simple, intuitive controls are equipped with auto and
manual blower modes. Optional sensors integrate filtration with welding
processes. Additional electronics monitor airflow and motor speeds to indicate
operating condition with green, yellow and red lights.
With user-friendly electronics and only requiring connections to electricity and
compressed air, the HVE Hi-Vac machine is simple to set up. Additional details
can be found in the section titled “Prerequisites for Use”.
Persons involved with installing, operating, maintaining, and servicing this
RoboVent HVE Hi-Vac machine must read these instructions prior to use. Keep
this manual in a safe and convenient place for reference. In the case of loss or
damage, please contact RoboVent for replacement.
RECEIVING & INSPECTION
The equipment will arrive on a pallet or in a crate. Perform a visual inspection
before removing from the truck. If there is any damage, it should be noted on
the shipping documents and photographed. It is the receiver's responsibility
to file shortage reports and damage claims with the carrier. The carrier is
responsible for any damage to the equipment while it is in transit. Notify
RoboVent if any damage has occurred so repair can be arranged.
The filter cartridge(s) will be shipped inside the machine.
Before discarding packing material, make sure no small parts are concealed
within wrapping.
SAFETY SIGNS AND SYMBOLS
Below are the safety symbols and meanings as used throughout this manual
and on the machine itself. Specific hazards and labels are shown in the
"Specifications" section.
Warning Sign: Yellow Triangle with black edging. Specific icon shown
on the face for specific concerns, or exclamation mark (as shown) for
generic safety alerts to hazardous conditions.
Prohibition Sign: White circle with red edging and crossbar. Specific
icon shown on the face for specific concerns, or STOP (as shown) for
generic alerts to conditions that may lead to damage to the job, machine
or other factor.
Mandatory Sign: Blue circle with white icon. Specific icon shown on
the face for specific concerns, for example as shown, it is mandatory to
consult the manual before operating.
Reference Sign: This symbol indicates that the reader should refer to
the specific section and read about this identified component, task or
location and learn more before continuing. Where this sign is shown, DO
NOT attempt to continue before reading the section as indicated.
PURPOSE & LIMITATIONS
The HVE Hi-Vac filtration machine is designed for use with fume extraction
welding guns in production applications. Its powerful suction, simple
controls, and small footprint are suited for use in many facilities, including
fabrication shops, production facilities, shipbuilding, and large structures.
This machine is intended for filtration of airborne fumes and non-explosive
dry dust captured at the source. The design and controls are optimized for
welding processes, especially when used with fume extraction welding guns,
but it can be used intermittently for related processes such as grinding or
sanding.

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Introduction
Whilst it can perform in ‘high-loading’ applications, such as robotic weld-
ing, plasma cutting, and grinding applications, these processes generate
more fume and particles than what is practical for the collection capacity
of the HVE Hi-Vac machine. Therefore, it is not recommended for use in
such applications.
Some welding conditions or atmospheres can generate oily or sticky
particulate that ‘blinds’ the filter media. Blinding occurs when the pores
in the fiber of the media become blocked so that pulse cleaning does not
remove the blockage, leading to diminished cleaning results, finally result-
ing in reduced filter life. If you notice decreased filter life, or if dierential
pressure of the filter does not drop after an oline cleaning cycle, it may
indicate blinding. You can improve filter condition by welding clean mate-
rial, reducing the amount of oil on parts, and/or limiting use of anti-spatter
spray. Nozzle gel must not be used with fume extraction welding guns.
Metal particulate collected from welding or related processes can be
combustible when built-up in the collector, on the filter, or in hoses.
Combined with the presence of sparks in the incoming air stream, this
presents a potential fire risk. Typically, turbulence in the hose extinguishes
sparks; for additional protection, the machine is equipped with a Delta3
Spark Arrestor. Despite these features, it may be possible for a spark to
get through. Observe the process periodically to ensure intake of sparks
is not excessive. Often, the position of inlets can be adjusted to prevent a
consistent intake of sparks or settings on the process can be adjusted to
reduce sparks.
Follow all regulations applicable to your workplace and usage conditions.
RoboVent or a consultant in your area can assist with compliance. If the
intake becomes obstructed, shut the machine down and fix the issue to
prevent overheating of the motor and blower. Overpressure is indicated by
the red band on the airflow gauge.
The blower motor is designed for continuous duty. Starting the motor more
than six times per hour, however, can decrease its life. When using the
AutoSaver function, it is possible for the number of starts to exceed this
count. The program delays shut-o for one minute after welding stops to
evacuate fumes from the hose and to allow for pauses between welds.
Pay attention to a typical production cycle: if there are breaks in welding
longer than one minute, keep track to make sure motor will not be required
to start more than six times per hour. If this frequency will be exceeded,
either switch the unit on before each period of welding, or leave the unit on
throughout the day.
Personal Protective Equipment (PPE) is required when servicing the
machine. Specific requirements are to be determined by applicable
regulations, dust toxicity testing and your workplace policies. As a
general rule, gloves, dust mask and safety goggles are recommended
to prevent exposure to or inhalation of dust.
Some dusts collected from welding and related processes can be
hazardous. The factory is responsible to test for toxicity and determin-
ing precautions for emptying and disposing hazardous waste.
The HVE Hi-Vac is not designed to filter gases, odors or noxious fumes.
This filtration machine is not approved for filtration of Carcinogenic,
Mutagenic, or Reproductively-harmful (CMR) substances.
The HVE Hi-Vac unit is not designed for use in explosive atmospheres,
potentially explosive atmospheres, or for extracting substances from
such atmospheres. Neither is it intended to process substance which
could create an explosive or potentially explosive atmosphere inside
the machine. If the dust to be extracted may create aforementioned
conditions, it must be sampled and tested for explosivity. Responsibility
lies with the factory to perform testing and ensure compliance with
NFPA guidelines.

FlexPro Hi-Vacuum Owner's Manual & Operating Instructions
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Introduction
PREREQUISITES FOR USE
All users and maintenance personnel must read this manual before
installing, operating, or servicing the RoboVent HVE Hi-Vac. Maintenance
personnel must thoroughly understand the troubleshooting and servicing
sections of this manual.
The machine requires compressed air and electrical connections:
• Compressed air must be regulated to 5.86 bar (85 PSI) and must be
clean and dry according to ISO 8573-1 Class 7. It is recommended to
connect to the machine with a ¾” hard pipe compressed air line.
• Electrical supply is dependent on collector, see rating tag for more info.
• Power cord and air connection are on right side of machine (if facing
control panel door).
The machine will require adjustment of airflow to ensure eective capture;
refer to the operating instructions. It is recommended to check airflow at the
beginning of each shift to ensure fumes are being captured and settings are
maintained.
The machine is limited by the amount of vacuum it can safely create.
Too much resistance by such conditions as unsuitable hose, excessive
hose length or constricted intake can overload the blower and
prevent it from successfully capturing fumes. Changes can be made
to setup if machine does not perform as expected. Review "Testing &
Commissioning" section If you need assistance with adjustment or
setup, please contact RoboVent Customer Service & Tech Support at
888-ROBOVENT.

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Specifications
SPECIFICATIONS CHART
Weight Full 565 lbs (257 kg)
Equivalent Filter Area 256 ft2(23.8 m2)
Maximum Airflow 140 CFM @ 80 in. w.c. (238 m3/hr @ 20 kPa)
Operating Temperature 10 – 50° C (50 – 120° F)
Cabinet Construction 11-gauge Steel, Polyester Powdercoat
Compressed Air Requirements Oline 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 Load Amps
Control Voltage 24 VDC
DATA PLATE INFO
Locate the data plate and record model number, serial num-
ber and manufacture date here for quick reference.
Model No:
Serial No:
Manufacture Date:

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Specifications
DIMENSIONS
95.18
31.26
31.26
31.26
13.38 4.45
29.00
17.75
3.12
28.18
64.12
32.91
13.81
31.26
22.93
12.60
7.83
DIMENSIONS
TOP
FRONTLEFT SIDE RIGHT SIDE

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Specifications
AIRFLOW SCHEMATIC
Muler cuts fan noise.
Particulate is pulsed o f
ilters and falls
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 o filter.
Particulate builds up
on filter.
Contaminated air
from process.
Spark and large
particle deflector.

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Specifications
COMPONENTS
Air tank
Regenerative motor/blower
assembly
Noise muler
Lifting lugs
20 Gallon particulate
containment drum with latches
Cartridge filter
Compressed air pulse valve
Electrical connection
Filter clamp mechanism
3-Inch diameter
dirty air inlet
Hopper
Control panel door
Filter door
Control panel

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Unpacking & Locating
Follow workplace safety guidelines when handling and unpacking this
machine. Gloves, safety glasses and safety footwear are recommended.
Set aside a 3 m ( 9 ft) work area to allow adequate space for shipping
material and lifting from pallet. Consider cordoning o to prevent traic
from entering the area.
ENVIRONMENTAL REQUIREMENTS & CONSTRAINTS
This machine is designed to operate in an environment with temperature
10 – 50° C (50 – 120° F) and relative humidity 40-70% (non-condensing).
The Spire machine is designed for use indoors. Floor surface must be hard,
flat, level, and capable of supporting 1.2 kg/cm2(17.6 psi) in order for the
unit to remain safely stable. Atmosphere must be mostly free from contami-
nants such as dust, oil mist, water and airborne chemical solvents.
If outdoor use is required, the machine must be sheltered from wind, blown
dust and precipitation. Storage must be indoors to prevent condensation in
control panel and motor areas.
Explosive Atmospheres
The machine is neither certified nor designed for use in explosive
atmospheres, potentially explosive atmospheres or for collecting explo-
sive dusts. The user is therefore strictly prohibited from using it in such
applications and conditions. Do not attempt to modify this machine for
the purposes of use in any explosive environment.
Lighting
The machine’s work area must be illuminated so that the control panel,
power cord connection and gauges are clearly visible without the need for
additional local lighting.
When servicing, additional temporary lighting may be needed by mainte-
nance personnel.
Vibration
This machine has been assessed and determined, that in normal design
use parameters, this machine oers no appreciable vibration hazards and
as such, does not require any remedial or secondary action to reduce
vibration.
Noise
The machine is designed in such a way as to oer reduced acoustic
sound pressure levels. The machine noise level will vary based on the
surrounding environment.
PROCESS FOR LOCATING
Inspect packaging and machine for missing parts or shipping damage as
described in the “Receiving & Inspection” section.
Use the following steps to unpack and locate:
1. Remove packing material and crating from sides.
2. Use a crane attached to lifting points to remove from pallet.
3. Set machine in place with forklift or crane. Connect to process(es)
with high-vacuum ducting.
4. Adjust airflow to ensure eective fume capture. Refer to operating
instructions.

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Testing & Commissioning
Once unit has been connected to power and compressed air, it is important
to verify the machine is operating correctly and adjust airflow to ensure
eective capture.
Record details of setup and settings through pictures and notes. Keep
these on file with a logbook for daily checks.
Verify Machine Operation
Perform these quick checks to verify machine is running correctly:
1. Turn unit on. Listen for blower to ramp up and level o at running
speed. Watch that KPI and Total Static Pressure changes on HMI.
2. Once the function has been confirmed, testing and adjustment can be
performed as required on VFD (if installed).

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Installation
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.
Set unit onto top of hopper using crane or forklift (diagram 1A). Open the
filter door and remove filter to provide access to all bolt areas. Using
provided bolts, wasters and sealing washers bolt cabinet to hopper (see
and 1C) through the filter door. Hook-up compressed air and electrical and
mount HMI and your HVE H-Vac machine is ready to go!
C
HVE-175-80-1-CAB
1/2" GASKET
PLAIN WASHER
BONDED
SEALING WASHER
M10 RIVNUT
HDH-175-80-1
ANSI B18.2.3.5M - M10 x 1.5 x 30
94709A418_NEOPRENE 18-8 SS BONDED SEALING WASHER
ANSI B18.22M - 10 N
3
2
1
Diagram 1A Diagram 1C
Diagram 1B

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Operating Instructions
Refer to diagram below for callouts of the control interface located on
control panel door. Below are descriptions of the simple control modes.
More than six starts of the motor in one hour can be harmful. Refer to
the “Purpose & Limitations” section for a detailed description.
Manual Mode Operation
Once airflow has been set up according to the “Testing & Commissioning”
section, manual mode is simple to operate – just on when you need it, o
when you don’t. The blower is rated for continuous duty, so it can run for a
complete shift if needed.
AutoSaver Mode Operation
The automatic mode is controlled by optional sensors on the weld unit‘s
power cord. The optional cables connect to the rear of the machine.
Simply turn the mode switch to the far right ‘auto’ position and begin weld-
ing. The sensor will detect an increase in power drawn by the welder and
signal the Spire unit to start.
Pulse Cleaning
The HVE Series Hi-Vac machine is equipped with electronic pulse cleaning.
Two modes are automatically activated, ‘online’ and ‘oline’. Online cleaning
pulses the unit after it has been running for 30 minutes continuously. Once
the unit has been shut o after a 30-minute or longer work period, an of-
fline pulsing cycle will be initiated.

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ePad Operation
System Control Page Blower Control Page
A System Control
Enables/Disables the system for blower
control. "Off" is under security. A login is
required to turn unit off.
A A
B B
C C
D D
D
C Auto Control
Enables RoboVent unit to be turned on
or off from a connected machine.
B Login
Allows customers to login with their
provided User Name and Password to
change parameters.
A Blower Control
Enables/Disables the blower to
run the collector.
C Fault Status
Message box which shows the current
condition for the Motor overload.
D 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.
B Blower Status
Message box which shows the
current status of the blower.

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ePad Operation
Pulsing Control Page Unit Hours Page
AA
B
B
C
C
D
A Maint. Pulse Select
Allows User to switch from automatic pulsing
and maintenance pulse down mode.
B Auto Online Pulse
Message box which shows the current status
of the Auto Online Pulse Cycle (On/Off).
C Auto Offline Pulse
Message box which shows the current status
of the Auto Offline Pulse Cycle (On/Off).
D 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.
A Total Machine Hours
Display showing the accumulated
machine hours.
B Hours Since Service
Display showing the accumulated machine
hours since service has been conducted on
the collector.
C Service Hours Reset
Service Hours reset button. When pushed
resets the Service Hours Meter to zero.

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ePad Operation
Service Messages Page Alarm Log Page
A
A
B
B
C
C
A Filter Service Message
Informs the operator that the filters need
maintenance.
B Suppression Tank Message
Informs the operator that the Suppression
Tank needs to be serviced.
C Collection Drum Message
For optional barrel sensor, informs the
operator that the collection drum is full and
needs to be emptied.
A Acknowledge All Alarms
Acknowledge all current alarms that are
active.
B Alarm Scroll Navigation Buttons
Allows for scrolling up and down by alarm
and page.
C 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).

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ePad Operation
System Settings Page System Settings Page
AA
B
C
A Blower Jog
Momentary contact to test blower rotation, etc.
B Pulse Test
Momentary contact that energizes pulse valve.
Helpful for diagnostics.
C Shut Down Delay
Amount of Time (in minutes) equipment continues
to run after the remote start signal ends.
A 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.

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eTell Operation
System Settings Page Warning and Alert Messages
A
A
B
B
D
D
C
C
Pulse Control Settings
There are (3) different Pulse
Modes. Online (while running),
Offline (after shutdown) and
maintenance ( at select times
to maximize filter 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: Number of times
each filter bank is pulsed
after blower shutdown.
Alarm Screen-
Blow-By Detected
This feature is very important.
It detects both when filters are
'leaking' as well as if there is
smoke present.
Temporary Bypass: Provides
for unit operation, Bypasses
detector for two minutes.
Alarm Screen-
Optional Equipment
Indicates the 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 Screen-
Emergency Stop Tripped
Indicates tripping of an E-stop.
Unit controls are completely
shutdown.
Alarm Screen-
Blower Overload
Electrical power overload
Escape; transfers to screen #2.

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Preventative Maintenance
Safety
Emptying the dust containment area, performing monthly service or
changing filters requires PPE to minimize exposure to metal dust. It is
recommended to wear disposable coveralls, non-porous gloves, dust mask
and safety goggles when performing these procedures. Follow company
MSDS and PPE guidelines.
Dust collected by this machine may be hazardous. Toxicity testing must
be performed by your local waster service provider and dust disposed of
according to local disposal and workplace safety regulations.
The Dust Containment Drum
Empty the dust containment drum as soon as it is full. The time between
changes will vary with production schedules, processes or other factors. A
good estimate of time required between drum changes can be determined
after a few changes; record percentage full and hours each time to help
you estimate when the next change is needed.
To empty the dust containment drum, follow these steps:
1. Complete a maintenance pulse to remove excess dust from filters.
2. Brush down the inside of the filter cabinet to knock down any dust to
the containment drum (removal of filters is not required).
3. Unlatch the dust containment drum and empty the contents
into waste disposal bin (or other means as required by site EHS
regulations).
4. Repeat the process for other drum (if applicable).
5. Replace dust containment drum and latch securely in place.
6. Record machine hours and service action.
Monthly Maintenance
On a monthly schedule, perform the following steps and checks:
1. Start machine, allow it to ramp up. Record machine hours and filter
dierential pressure. Turn machine o once values are recorded.
2. Machine will start oline pulse sequence.
3. Once pulsing has finished, open filter cabinet and brush any piles of
dust into containment drum at bottom.
4. Inspect inside of cabinet and vacuum out large build up of dust.
5. Close filter compartment and start machine again.
6. Record post-cleaning filter dierential pressure.
7. If filter dierential pressure is 3.5 or higher, it is time to replace your
filters. Contact RoboVent at 888.ROBOVENT.
Filter Change
Once the filter dierential pressure gauge has reached 3.5 KPA, it is time to
replace the filter.
Perform the procedures outlined in monthly maintenance. While filter
compartment is open, and once cleaning of dust build-up is complete,
replace the existing filters (see part number reference on page 21).

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Replacement Parts
Description Item # Qty.
Cartridge filters: PL-14D26-M11-SF 1
PL-14D26-A15-SF 1
EX-14D26-B16-SF 1
Motor & Blower Wheel Combo HVE-BLR-175 1
Andon Light HS-3C-24 1
HMI Screen HMI-EPAD 1
Pulse Valve DV-10-TU 1
Pulse Nozzle NS-SPR-200 1
Filter Regulator - 3/4" FR-34 1
Minihelic Gauge MHG-60 1
Inlet Filter IL-FLT-2 1
20 Gallon Drum DR-20 1
RoboVent Customer Service:
For replacement parts, service or to speak to a representative,
contact RoboVent at:
Phone: 888.ROBOVENT
Email: [e-mail]