c series conveyor troubleshooting guide

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 informationnecessary for the successful installation, op-eration and maintenance of your unit. Westrongly recommend that this manual becarefully studied prior to installation or opera-tion. Doing so will avoid the possibility of in-advertent damage or malfunction of theequipment. Following the recommendedmaintenance instructions will ensure betterperformance and extended equipment life.

Also included within this manual is a list ofrecommended spares. These items are sub-ject to wear during normal use. We recom-mend that they be purchased in advance andkept in stock to avoid possible down time andfuture delays.

Because PIAB equipment may be shipped aspart of an installation involving other types ofequipment, or dissimilar units are sometimesconnected to perform specific functions, youshould familiarize yourself with the manualscovering 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 toensure many years of trouble-free operation.In the event that parts or technical assistanceis required, please contact us at:

PIAB USA, Inc.

65 Sharp Street

Hingham, MA 02043

Ph: (800) 321-7422/ (781) 337-7309

Fax: (781) 337-6864

[email protected]

www.piab.com

It is the users' responsibility to operate thisequipment in a safe manner and ensure com-pliance with all applicable safety laws andcodes.

WARRANTY:

PIAB Vacuum Conveyors are thoroughly in-spected and tested before shipping. EachPIAB Vacuum Conveyor is warranted to befree of defects in workmanship and materialsfor five years from date of purchase (filter andwear 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 personwho installs the conveyor in another main system hasthe responsibility of carrying out a risk analysis whenthis is desired.

Dust explosions

When handling and conveying dry powders and mate-rial consisting of small particles, there is a risk that adust explosion may occur. A dust explosion may occurwhen certain finely divided materials are mixed with air(oxygen) and then are ignited by, for example, a spark.

In order to minimise the risk of dust explosions, all in-cluded parts of the conveying system must be connect-ed to one and the same point of earth (equipotential)according to applicable regulations. It is also importantnot to smoke, weld or carry out other work where therisk of generation of sparks may be present in the vi-cinity of the conveyor.

In the table below are some examples of materials thatmay cause dust explosions.

The conveyor may not be used in explosive surround-ings containing the following gases: acetylene, carbondisulphide, hydrogen, hydrogen sulphide and ethyleneoxide.

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

It is important to check and clean/change filters at reg-ular intervals so that they are not clogged, as thismight lead to the fact that the filters will be subjectedto overload, and that undesired matters or particlesleak from the conveyor.

Emergency stop

The system builder shall provide the machine with anemergency stop function. As an option to the vacuumconveyor there is a remote control box with a built-inemergency stop function.

Start/stop of the conveyor

The conveyor is started either with the provided controlunit or via another main control system. The conveyorstops 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 pointand may cause injuries to eyes and mucous mem-branes.

u Never aim a suction tube, a feed nozzle or a hose at anyone.

u The larger the suction inlet, the higher the power and danger.

u The installation must be made so that the inlet cannot contact the operator and other people.

u Always remember to disconnect the supply of compressed air when cleaning or servicing the vacuum conveyor.

u

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 pumpmay, in certain applications, constitute a risk andcause injuries. If the filter is not fully intact when pow-der with small particles is conveyed, the particles maypenetrate the filter and enter the pump, and further onout 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 casesthe pump shall be fitted with a central exhaust with anexternal filter. In certain cases, another alternativecould 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 whencleaning or servicing the vacuum conveyor

Compressed air

We recommend that compressed air of at least qualityclass 3 is used (ISO norm 8573.1) for PIAB’s vacuumpumps. This means that only a maximum of 5 mg/m3

of a maximum of 5 µ size particles may be present inthe compressed air.

For the USDA conveyor to conform to the American re-quirements of the authorities, the air for the air shockmust be delivered according to 3-A Accepted PracticeNo. 604-04. This means, among other things, that theair 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 rememberthat push-in connections with built-in non-return valvesmay cause pressure drops. Also, take into consider-ation that there may be other devices in the com-pressed-air network that might consume compressedair.

Dimensioning of the compressed-air pipeline

A very important part of a vacuum system is correctlydimensioned hoses and connections. In order to getthe highest possible performance from each vacuumpump, 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 pipelineis longer than 10 m (33 ft), select a pipeline of a largerdiameter.

Installation of compressed air

The feed pressure of the compressed air is between0.4 (58) and 0.6 (87 psi) MPa for PIAB vacuum convey-ors and pumps. Careless usage of compressed air maycause 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 whencleaning or servicing the vacuum conveyor.

You are responsible for your own and other people’ssafety at the place of work.

Contact your local PIAB distributor if you have anyquestions.

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

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Disconnecting the compressed-air pipeline

Before the compressed-air pipe of the pump is discon-nected the pressure to the compressor must be turnedoff. After that, the pipeline may be disconnected.

Dismounting the conveyor

It important that the conveyor is emptied of its powderbefore dismounting is started. The compressed-airsupply must be disconnected before dismounting theconveyor.

Mounting of the conveyor

The conveyor is delivered mounted. When mounting itafter cleaning/servicing, it is important that seals andfilters are mounted correctly so that leakage does notoccur. C21 and C33 shall be anchored at one point atleast (either at the bottom valve unit or at the connec-tion girdle). C56 shall be anchored at two points atleast (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 easilystart and stop the conveyor.

Remote control of the conveyor

When using remote control, the system builder shouldensure that the conveyor can not be simultaneouslyoperated from two locations.

Installation of the conveying pipeline

Correct dimensioning and installation is A and O for thesystem 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 unitsor pipe emptying function. It is important that the pipe-line system is sealed in order to prevent the conveyedpowder from leaking from the equipment to causedamage to other devices and injuries. It is also impor-tant to make sure that no foreign matters can inadvert-ently be sucked into the conveyor.

Some basic tips

u The conveying pipeline should be installed without

having any unnecessary bends.

u Avoid inclined rises in the conveying pipeline.

u The radius of the pipeline should be at least 10

times the pipe diameter.

u Choose pipes instead of hoses where possible.

u Avoid all types of edges and restrictions at pipe

joints and connections.

Noise level

The measured noise levels (72–76 dBa) have beenmeasured in the following manner. The distance be-tween the pump and sound level meter = 1 metre. Thehigher measuring value applies to the exhaust air-flowin the direction of the sound level meter and the lowermeasuring value applies to the exhaust air flowingfrom the sound level meter. Please notice that thenoise level of the conveying depends on the kind ofpowder that is conveyed.

VACUUM CONVEYORS

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CONNECTION EXAMPLESCONTROL 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 550ART. NO. 01 04 552

VACUUM CONVEYORS

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

VACUUM CONVEYORS

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

VACUUM CONVEYORS

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CONTROL UNIT CU-2A/B ART. NO. 01 04 540ART. NO. 01 04 548

VACUUM CONVEYORS

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CONTROL UNIT CU-2A/B WITH FLUIDISATION AND LEVEL DETECTOR ART. NO. 01 04 540ART. NO. 01 04 548

VACUUM CONVEYORS

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CONTROL UNIT CU-2A/B WITH FLUIDISATION ART. NO. 01 04 540ART. NO. 01 04 548

VACUUM CONVEYORS

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CONNECTION EXAMPLES

VACUUM CONVEYORS

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VALVE UNIT VCC-EP

VALVE UNIT VCC-EP WITH FLUIDISATION

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ACHIEVING THE DESIRED RATE

Is the air pressure at least 87 psi entering into the pump, in the proper line size, and with enough volume?

A. If the conveyor is functioning fine but the rate needs to be changed, try adjusting the timers. Since each ma-terial conveys in a different manner, there are not particular on and off times that will achieve certain rates. Ifthe material has all been dumped out and the bottom door remains open, the off time can be shortened. Tryminor adjustments, increasing the on time and decreasing the off time. The off time may need to be increasedas the on time is increased to avoid packing the material in the conveyor.

Note: The conveyor has a maximum internal volume, please consult the user manual for your specific conveyor.

B. If the product tends to move in slugs (big clumps of material that fill the line) or dense phase, increased aspi-ration may be necessary. The easiest way to add more air is at the feed point.

1. Feed Wand - The standard feed wands include two places to adjust the aspiration. The black piece atthe top of the wand twists around the wand, covering or uncovering openings in the actual wand. The morethe openings are uncovered, the more air that is allowed to enter the system. In order to rotate the blackpiece; unscrew the bottom wing nut. Retighten when the desired amount of opening is uncovered.

a.The inside tube can be adjusted up or down. If the tube is all the way down, touching the cage, therewill be less aspiration and a greater amount of product picked up. If the tube is pulled out to be evenwith the outer tube, there will be increased aspiration and a decreased amount of product picked up.The tube can be adjusted by unscrewing the top wing nut.

2. Feed Adapter - The standard feed adapters include two ball valves. Both are adjustable which allow in-creased aspiration.

a. If the material is not flowing easily into the cone on the feed adapter, the ball valve closest to thecone should be opened up until the product freely flows. This ball valve is attached to a pipe that shouldbe extended all the way out, approximately 8.5". If the material will not even flow into the cone, sometype of aspiration or agitator may need to be added before the feed adapter. The second ball valveshould be opened more if the material is conveying in dense phase.

b. If the material is very free flowing, it may drop from the cone into the perpendicular tube and clogthe tube. If this is the case, push the ball valve attached to the inner tube in closer to the cone.

3. Injection Valve - An injection valve can be added into a system no matter which feed method is beingused. There are two types of injection valves. The first type of injection valve has a ball valve that can beopened for increased aspiration. The second type of injection valve senses a high vacuum and allows as-piration as needed

Conveyor Min. Compressed Air Line

Max. Required Volume (scfm)

C21 100 classic .25 "14.8

C21100 .5 "14.8

C series 200 .5 "29.7

C series 400 .5 "59.0

C series 600 1.0 "89.0

C series 800 1.0 "118.6

C series 1200 1.0 "178.0

C series 1600 1.0 "237.3

VACUUM CONVEYORS

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C. If there is little to no transport of material with a low vacuum, but the conveyor is still cycling properly.

1.The seals in between the modules may be cracked and leaking.

2.There may be a loose connection somewhere with the hose.

3.There may be too much aspiration.

a. If a sensing injection valve is being used, make sure the feed pressure is between 58-87 psi. If thefeed pressure is over 87 psi, the injection valve will remain open all of the time.

4.The seals inside of the pump may be cracked or worn. Refer to page 27.

5.Does the bottom flap close? - If not please turn to the section with the proper controller.

D. If there is little to no transport of material with a high vacuum, but the conveyor is still cycling properly.

1.The filter may be clogged.

2.Aspiration may need to be added.

3.There could be a clog in the pipeline.

4.The pump may be filled with material.

E. If there is material packed into the conveyor, and it is not dumping out properly.

1.The on time may need to be decreased.

2.The off time may need to be increased.

3.The material may be too damp.

a.The product may be sticky.

b.The compressed air may be damp, adding air to the material being conveyed.

4. Fluidization may need to be added to the conveyor. If it is already part of the conveyor, it may not be

functioning properly. The material would be stuck in the cone section located at the bottom of the convey-or.

5.The filter air shock may not be working properly.

F. If the filter air shock does not function properly, there wouldn't be a 'bump' to shake the excess material off ofthe filter. This can be heard when the bottom flap door opens.

1.Check the connections, both compressed air and from the air shock to the pump.

2.Make sure there is not a kink in the tubing to the air shock.

3.If the tubing has material in it, the tubing must be cleaned out or replaced.

4.The valve on the filter shock should push in and out easily. If not, clean it off and add a little lubrication.

5.If the air shock still won't function properly, the air shock valve may be defective.

G. If there is material coming out of the exhaust of the pump, there is a filter problem.

1.The filter may be worn and need to be replaced.

2.The filter may have been put on wrong. Please refer to diagram on page 18, 19.

3. In either case, the side plate should be removed to look inside of the pump. For optimum performancethere should not be any material in the pump, especially the nozzles. Please refer to page 23 for directionson maintaining and cleaning the pump.

VACUUM CONVEYORS

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FILTER REPALCEMENT1

2 3

4 5

VACUUM CONVEYORS

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6 7 8

9 10

11 12

VACUUM CONVEYORS

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FILTER CLEANING

7

It may be necessary to clean the filter elements under certain circumstances, e.g. after a change of product. In this case, you are welcome to draw on our experience! We shall be glad to help you choose the best cleaning method.

PITEX CLEANING

HERDING SINTERED BRUSH OFF CLEANING

cleaning procedure:1. Your filter elements have to be dismantled in order to be cleaned. 2. Place soiled filter element into washing machine at or below 40ºC (104ºF), with mild detergent. Or you may handwash your filters. 3. Do not machine dry your PITEX filters. 4. Place filters on wire shelf. Allow filter to air dry completely before re-installation. 3. Reinstall the ddry PITEX filter elements in the filter unit.

Brush-off cleaning procedure:1. Your filter elements have to be dismantled in order to be cleaned. 2. Stand the filter elements in a vertical a position as possible (e.g. lean them against a wall, see the drawing). 3. No dust should be allowed to get into the filter elements during the cleaning operation. It is recommended, therefore, to cover up the inside of the filter (e.g. with adhesive tape). 4. Brush off the dust with a soft brush -Bristle length: 75mm (3”) -Bristle diameter: 0.7mm (0.025”) -Bristle material: Nylon or PVC Brush off the dust from top to bottom a maximum of 2 times, applying just a little pressure -Contact pressure: 5N (1.1 pound force) 5. Turn the filter elements and proceed in like manner for the rear and the narrow sides. 6. Clean the head and foot zone last, taking care not to allow any dust to get into the filter elements. 7. Reinstall the filter elements in the filter unit.

VACUUM CONVEYORS

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HERDING SINTERED RINSE OFF CLEANING

HERDING SINTERED AIR JET CLEANING

Rinse-off cleaning procedure:1. Your filter elements have to be dismantled in order to be cleaned. 2. Stand the filter elements in a vertical a position as possible (e.g. lean them against a wall, see the drawing). 3. No dust should be allowed to get into the filter elements during the cleaning operation. It is recommended, therefore, to cover up the inside of the filter (e.g. with adhesive tape). 4. Rinse off the dust with gentle water pressure -Maximum pressure of thewater jet upon impact: 1 bar (14.5 psi) -Maximum water temperature: 40°C (104F) 5. Turn the filter elements and proceed in like manner for the rear and the narrow sides. 6. Clean the head and foot zone last, taking care not to allow any water to get into the filter elements. 7. Leave the filter elements standing at the same acute angle to dry. Drying must take place at room temperature (minimum 24 hours). 8. Reinstall the ddry filter elements in the filter unit.

Air-jet cleaning procedure:1. Your filter elements have to be dismantled in order to be cleaned. 2. Stand the filter elements in a vertical a position as possible (e.g. lean them against a wall, see drawing above). 3. No dust should be allowed to get into the filter elements during the cleaning operation. It is recommended, therefore, to cover up the inside of the filter (e.g. with adhesive tape). 4. Clean off the dust with a gentle air jet -Maximum pressure of the air jet upon impact: 1 bar (14.5 psi) 5. Turn the filter elements and proceed in like manner for the rear and the narrow sides. 6. Clean the head and foot zone last, taking care not to allow any dust to get into the filter elements.8. Reinstall the filter elements in the filter unit.

VACUUM CONVEYORS

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GORE SINBRAN BRUSH OFF CLEANING

GORE SINBRAN RINSE OFF CLEANING

Brush-off cleaning procedure:1. Your filter elements have to be dismantled in order to be cleaned. 2. Stand the filter elements in a vertical a position as possible (e.g. lean them against a wall, see the drawing). 3. No dust should be allowed to get into the filter elements during the cleaning operation. It is recommended, therefore, to cover up the inside of the filter (e.g. with adhesive tape). 4. Brush off the dust with a soft brush

-Bristle length: 75mm (3”) -Bristle diameter: 0.7mm (0.025”) -Bristle material: Nylon or PVC

Brush off the dust from top to bottom a maximum of 2 times, applying just a little pressure

-Contact pressure: 5N (1.1 pound force) 5. Turn the filter elements and proceed in like manner for the rear and the narrow sides. 6. Clean the head and foot zone last, taking care not to allow any dust to get into the filter elements. 7. Reinstall the filter elements in the filter unit.

Rinse-off cleaning procedure:1. Your filter elements have to be dismantled in order to be cleaned. 2. Stand the filter elements in a vertical a position as possible (e.g. lean them against a wall, see the drawing). 3. No dust should be allowed to get into the filter elements during the cleaning operation. It is recommended, therefore, to cover up the inside of the filter (e.g. with adhesive tape). 4. Rinse off the dust with a gentle water jet -Maximum pressure of the water jet upon impact: 1 bar (14.5 psi) -Maximum water temperature: 120°C (248F) 5. Turn the filter elements and proceed in like manner for the rear and the narrow sides. 6. Clean the head and foot zone last, taking care not to allow any water to get into the filter elements. 7. Leave the filter elements standing at the same acute angle to dry. Drying must take place at room temperature (minimum 24 hours). 8. Reinstall the ddry filter elements in the filter unit.

VACUUM CONVEYORS

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CLEANING AND MAINTAINING THE VACUUM PUMP

PIAB vacuum pumps are easy to clean and maintain. The only wear parts in the pumps are flap valvesand gaskets. A slow, gradual loss in vacuum could be attributed to cracked gaskets or flap valves.Please refer to pages 26 for a spare parts breakdown. The spare kits include all of the necessary flapvalves, gaskets, and a compressed air filter.

A slow gradual loss in vacuum could also be attributed to product moving through the pump. If anymaterial has come out of the exhaust, chances are the pump needs to be cleaned out.

Classic and L 100 vacuum pumps

The pump should be opened up and examined. Please refer to page 31 for a diagram and parts break-down of the Classic 100. First the panel plate should be removed, and then the side plate. The valveplate and side plate gasket is now visible. Located underneath the valve plate are the flap valves. Arethe gaskets or flap valves cracked? If so, the repair kit 32.01.069 should be purchased. The vacuumchambers and nozzles should now be visible. Is the material that is being conveyed in the chambers ornozzles? For optimum performance, there should not be any material in the pump. The pump's perfor-mance decreases as more material gets lodged in the nozzles. Please be careful when cleaning thepump. If a nozzle is broken off or rotated, the pump will need to be replaced. To remove material fromthe nozzles or chambers, PIAB suggests soaking the pump in water or in water with mild detergent suchas dishwashing detergent. Once the pump has new seals and flap valves and it is clean and put backtogether, it should run just like a brand new pump.

L100, L200, L400, L600, L800, L1200, L1600 vacuum pumps

The pump should be opened up and examined. Please refer to page 26-30 for a diagram and partsbreakdown of the vacuum pump. First the left side plate and gasket should be removed. This should ex-pose the vacuum chambers and nozzles. If the vacuum port is facing down, then the flap valves are lo-cated at the top of each vacuum chamber. Are the gaskets or flap valves cracked? If so, the appropriaterepair kit should be purchased. Is the material that is being conveyed in the chambers or nozzles? Foroptimum performance, there should not be any material in the pump. The pump's performance decreas-es as more material gets lodged in the nozzles. Please be careful when cleaning the pump. If a nozzleis broken off or rotated, the pump will need to be replaced. To remove material from the nozzles orchambers, PIAB suggests soaking the pump in water or in water with mild detergent such as dishwashingdetergent. Once the pump has new seals and flap valves and it is clean and put back together, it shouldrun just like a brand new pump.

VACUUM CONVEYORS

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TROUBLESHOOTING

*Optional part

Type of trouble Cause Position

Poor/no conveying

Low/no vacuum

Low/no pressure in compressed-air pipeline 1 Compressed-air connection

Leakage at seals 3 Seals

Too much carrier air 7 Valves for carrier air

Bottom lid is open/does not work 5 Bottom lid

Hose connection of filter shock/pump is defective 4 Filter shock

Leakage in conveying pipeline/joints 8 Conveying pipeline

High vacuum

Clogged/contaminated filter 2 Filter

Filter shock does not work- clogged filter 4 Filter shock

Too long pump time/short emptying time 9 Control unit

Too little carrier air 7 Valves for carrier air

Damp powder

Clogged conveying pipeline 8 Conveying pipeline

The powder sticks to the inside of the conveyor

Fluidisation does not work/is missing 6 Cone/fluidisation*

Damp powder

Too long pump time/short emptying time 9 Control unit

The filter shock does not work 4 Filter shock

The filter shock does not work

Hose connection of filter shock/pump is defective 4 Filter shock

The valve of the filter shock is defective/contami-nated

4 Filter shock

Low/no pressure to compressed-air pipeline 1 Compressed-air connection

Overfilling of the conveyor Too long pump time/short emptying time 9 Control uni

Powder dust from the pump exhaust Filter defective/incorrectly mounted 2 Filter

VACUUM CONVEYORS

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TROUBLE SHOOTING GUIDE: PIAB L SERIES PUMP

Problem Possible Causes Possible SolutionsPump will not turn on u On/Off knob safety clip has not been

removed·Ball valve found next to regulator

is in the closed position

u No compressed air available

u Check to be sure safety clip has been

removed and on/off knob is functioning

properly

u Be sure ball valve is turned so handle is

inline with compressed air line

u Problem with plant compressor or feed

lines, call maintenance

Low vacuum level observed on the pump gauge u Compressed air being fed to the pump is not

at high enough pressure

u Not enough volume of compressed air get-

ting to the pump

u On/Off knob is not fully in on position

restricting air flow

u Ball valve is not open 100% and is restricting

air flow

u Pump is not seated properly on the module

seal

u Module seal is torn or caked with material

causing a leakage point

u A Plug used on connections for tubing going

to control unit is loose or missing

u Leakage is being caused due to the surface

the seal/pump/cover unit was placed on

being dirty, rough, or uneven.

u Something is damaged inside the pump.

Pump is clogged with material, ejector noz-

zles have been damaged, or seals and gaskets

need to replaced.

u Read pressure level on the regulator gauge

while pump is running, if too low adjust

regulator dial until desired pressure of

87psi is reached

u If 87psi cannot be reached on the regulator,

there is not enough volume of air to feed

the pump. Make sure compressed air line

diameter is the proper size and increase if

too small. If diameter correct or larger,

than you need to live with the problem, use

a smaller size pump requiring less air, or

shut off other machinery using air so vol-

ume to pump will increase

u Make sure On/Off knob is pushed com-

pletely in against the pump face

u Adjust ball valve so it allows full volume

of air to flow through compressed air line

(align handle w/ compressed air line)

u Adjust pump/cover unit so it is properly

seated on the seal

u Inspect seal for any tears, worn spots, or

excess material buildup. Clean or replace

as necessary.

u Check 6mm, 8mm, and 12mm plugs used

on air manifold block. Make sure all plugs

are present and are pushed securely into the

fittings (especially the 12mm plug, you

must push very hard to get this plug

entirely into the fitting). Insert any missing

plugs

u Clean away debris if possible or find a new

smooth even surface to place seal/pump/

cover unit onto

u All possible problems listed above have

been checked and found to be correct.

Problem is internal to pump, call mainte-

nance

Pump will not shut off u On/off Knob is not fully in off position

allowing air to bleed into pump

u Something is damaged inside the pump not

allowing internal shuttle valve to function

properly

u Make sure on/off knob is pulled completely

out, into the off position

u On/off knob is pulled completely out, in

the off position and pump continues to run.

Problem is internal to the pump, call main-

tenance

VACUUM CONVEYORS

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L100 - L1200 COMPONENTS

Spare Parts Kit

3101091(V)(E) Spare Kit MLL100-400, co

nsisting of

:3101140 Flap valve, 3 pcs

.3101136 Side plate gasket, 2 pcs.

3101134 Inlet gasket

MLL200-400, 1 pc

3101092(V)(E) Spare Kit MLL600-800, consisting of

:3101141 Flap valves 300, 3 pcs.

3101136 Side plate gasket, 2 pcs.

3101135 Inlet gasket

MLL800-1600, 1 pc

3101099(V)(E) Spare Kit MLL1200, consisting of:

3101380 Flap valves 400, 3 pcs.

3101136 Side plate gasket, 2 pcs.

3101135 Inlet gaskets

MLL800-1600, 1 pcs.

VACUUM CONVEYORS

27

Pos. Art. No. Designation Number

MLL200

3101056

MLL400

3101057

MLL800

3101058

MLL800

3101058

1 31 00 025 Housing incl. nozzles MLL200 1

31 00 026 Housing incl. nozzles MLL400 1



2 31 00 053 Silencer internal MLL 100-400 complete 1 1

31 00 055 Silencer internal MLL 600-800 complete 1

31 00 082 Silencer internal MLL 1200 complete 1

3 31 00 054 Silencer external MLL100-400 complete 1 1

31 00 056 Silencer external MLL600-800 complete 1

31 00 083 Silencer external MLL 1200 complete 1

4* 31 01 140 (V)(E) Flap valve 148 3 3

31 01 141 (V)(E) Flap valve 300 3

31 01 380 (V)(E) Flap valve 400 3

5 31 01 138 Side plate, left 1 1 1 1

6 31 01 137 Side plate, right 1 1 1 1

7* 31 01 136 (V)(E) Side plate gasket 2 2 2 2

8 31 01 174 Panel holder 148 2 2

31 01 175 Panel holder 300 2

31 01 377 Panel holder 400 2

9 31 01 016 Panel MLL 100, 400, complete 1 1

31 01 017 Panel MLL 600-800, complete 1

31 01 018 Panel MLL 1200, complete 1

10 31 00 029 Remote valve G1/2" without filter housing 1 1 1 1

11 31 07 170 Barrel nipple KR1/2" - KR1/2 "1 1 1 1

12 31 07 031 Hose connector M5 D=2 incl. washer 4 4 5 5

14 31 07 212 Plug R1/8 "2 2 2 2

15 31 13 743 Nylon washer D=14 x 9,8 x 1 2 2 2 2

16 3113752 Screw MFX 4 x 10 A2 22 22 22 22

17 31 07 223 Compressed air filter 1 1 1 1

18 31 07 120 Filter housing 1/2" remote valve 1 1 1

31 07 291 Filter housing 3/4" remote valve 1

19 33 90 196 Straight adaptor 1/2" D=12 1 1

20 31 07 739 Hose connector 12-1/2 "1 1

21 31 01 131 Inlet gauze MLL 200-400 1 1

31 01 132 Inlet gauze MLL 800-1200 1 1

22* 31 01 134(V)(E) Inlet gasket MLL 200-400 1 1

31 01 135(V)(E) Inlet gasket MLL800-1600 1 1

23 31 16 124 Connecting flange MLL200-400 1 1

31 16 128 Connecting flange MLL800-1200 1 1

24 31 13 664 Screw MC6S 5 x 20 A2 8 8

31 13 669 Screw MC6S 6 x 20 A2 8 8

25 31 13 728 Nylon washer D=5,3 x 10 x 1 8 8

31 13 614 Nylon washer D=12,5 x 6,4 x 1,6 8 8

26 31 01 400 Cover plate MLL 1 1 1 1

27 31 01 401 Sealing Cover plate MLL 1 1 1 1

29 33 90 606 Reducer 6/4 2 2 2 2

30 33 90 306 Angle connection D=6 2 2 2 2

31 33 90 601 Nylon hose D=6/4 0.1m 0.1m 0.1m 0.1m

VACUUM CONVEYORS

28

MLL PANEL COMPONENT

Pos. Art. No. Designation Number

Panel

MLL 200,400

31.01.017

Panel

MLL600,800

31.01.017

Panel

MLL1200

31.01.018

1 31 01 366 Panel MLL 200, 400 1

31 01 368 Panel MLL 600 800 1

31 01 376 Panel MLL 1200 1

2 31 01 602 Vacuum gauge 1 1 1

3 31 07 072 Quick connection JG 6/4-M5 1 1 1

4 31 07 074 Quick connection JG 6/4-M5 1 1 1

5 31 07 010 Actuating valve 1 1 1

6 31 16 055 Shuttle valve 1 1 1

7 31 07 031 Hose connector M5, D=2 with washer 5 6 6

8 31 07 645 Hose 4x2 polyurethane 1.1m 1.2m 1.2m

9 31 01 603 Manometer 1 1

VACUUM CONVEYORS

29

INSIDE COMPONENTS OF MLL PUMPS

VACUUM CONVEYORS

30

INSIDE COMPONENTS OF COMPRESSED AIR INLET FOR MLL PUMPS

Pos. Art. No. Designation

17 31.07.111 Barrel Connector R3/8

17 31.07.194 Barrel Connector M24xM24

25 31.07.031 Hose Connector M5 D=2

26 31.07.030 Hose Connector M5 D=4

27 31.16.055 Shuttle Valve

28 31.07.626 Hose, Nylon 4x2

29 31.07.640 Hose, Nylon 6x4

30 31.07.120 Filter Housing 1/2"

30 31.07.291 Filter Housing 3/4"

32 31.07.223 Compressed Air Filter

31 31.13.739 O-ring 34.2x3 nitrile

33 31.07.116 Valve Housing

34 31.13.626 O-ring 11.5x3 nitrile

34 31.13.803 O-ring 16x3 nitrile

35 31.07.115 Piston for remote valve

35 31.07.191 Piston for remote valve

36 31.13.627 O-ring 24.2x3

37 31.07.119 Cover for Remote Valve

VACUUM CONVEYORS

31

L100 CLASSIC COMPONENTS

VACUUM CONVEYORS

32

L100 CLASSIC COMPONENTS

Spare parts list for MLD100 34.01.072used for C21 Conveyor

Pos. Art. No. Designation MLD100

1 32.00.002 Housing L/1 1

2 32.00.008 Int Housing incl Nozzle 1

3 32.01.103 Valve Plate DC 1

4 32.01.106 Side Plate HLM 1

5 32.01.134 Panel L250D 1

6 31.01.613 Vacuum Gauge 1

7 32.01.111 Exhaust Plug 4

8 32.01.109 Body Gasket 2

32.01.109V Body Gasket Viton (2)

32.01.109E Body Gasket EPDM (2)

9 32.01.110 Side Plate Gasket 1

32.01.110V Side Plate Gasket (1)

32.01.110E Side Plate Gasket (1)

10 32.01.126 Compressed Air Filter 1

11 32.01.141 Cover Plate 250 1

12 31.01.304 Flap Valve Nitrile 2

31.01.304S Flap Valve Silicone (2)

31.01.304V Flap Valve Viton (2)

31.01.304E Flap Valve EDPM (2)

13 31.01.305 Non-Return Valve Nitrile (1)

31.01.305V Non-Return Valve Viton (1)

31.01.305E Non-Return Valve EDPM (1)

14 31.13.755 Screw MFX 4x30 12

15 31.13.752 Screw MFX 4x10 2

16 33.51.171 Comp Air Nipple 1/8” 1

31.13.652 O-Ring D=9.19x2.6 1

17 33.51.170 Nipple Vacuum 3/4” 1

31.13.890 O-Ring D=22.22x2.6 1

32.01.069 (V) (E) Classic 25-120 Parts Kit

Non-Return Valve 31.01.305 excluded in the Conveyor Pumps

VACUUM CONVEYORS

33

TROUBLESHOOTING GUIDE: CONTROL UNIT CU-1B, PART # 01.03.919

Problem Possible Causes Possible SolutionsNo air to the control unit u Air is shut off

u The 6mm tubing is not connected

u Connect the air supply to the pump (40-100

psi)

u Connect the 6mm tubing to the manifold of

the pump and the 6mm connection on the

control unit

u Turn the compressor ON

u Locate the ball valve for the incoming air

supply

u Open the ball valve

The control unit did not cycle u The color-coded tubing are not connected

correctly

u The color-coded tubing is not pushed com-

pletely into connectors

u The timers are set correctly

u The ON-OFF knob is not in the on position

u Port # 8 (level control) is not plugged

u Port # 6 (fluidization) is not plugged

u Remote Start/Stop connectors are not in

place

u Follow the color for each function of the

control unit

u Connect corresponding color tubing with

matching control function port

u Push the control tubing completely into

control connectors

u Set the timers (A=5sec, B=2sec)

u Turn the ON-OFF knob on the left side of

controller once to "1"

u Put 4mm plug into port #8 (level control)

u Put 4mm plug into port #6 (fluidization)

u Put 4mm plug into port #44, jump using a

4mm tubing between port #42 and port #43

The control unit did not cycle u Component problem inside the control unit u Call PIAB, 1-800-321-7422 to arrange

repair or replacement

Connections for inlets and outlets

NOTE! The connections must be plugged when not in use.

Indications on the control unit

Nylon tube dimension OD/ID

Marking/tube colour Port Function

P-in 6/4 Black 1 Air supply input

Open valve 4/2 Blue 2 Opens bottom valve

Filter shock 4/2 Brown 3 Filter shock signal

Pipe empty 4/2 Transparént 4 Pipe emptying signal

Close valve 4/2 Yellow 5 Closes bottom valve

Fluid 4/2 White 6 Fluidisation signal

Pump 4/2 Green 7 Vacuum pump start signal

Level control 4/2 Grey 8 Level detector

VACUUM CONVEYORS

34

TROUBLESHOOTING GUIDE: CONTROL UNIT CU-2B, PART # 01.03.921

Problem Possible Causes Possible Solutions

No air to the control unit u Air is shut off


u Connect the air supply to the pump (40-100

psi)

u Connect the 6mm tubing to the manifold of

the pump and the 6mm connection on the

control unit

u Turn the compressor ON

u Locate the ball valve for the incoming air

supply


The control unit did not cycle u The color-coded tubing are not connected

correctly


pletely into connectors

u The timers are set correctly

u The ON-OFF knob is not in the on position

u Port # 8 (level control) is not plugged

u Port # 6 (fluidization) is not plugged

u Remote Start/Stop connectors are not in

place

u Follow the color for each function of the

control unit

u Connect corresponding color tubing with

matching control function port


control connectors

u Set the timers (A=5sec, B=2sec, C=5sec

u Turn the ON-OFF knob on the left side of

controller once to "1"

u Put 4mm plug into port #8 (level control)

u Put 4mm plug into port #6 (fluidization)

u Put 4mm plug into port #44, jump using a

4mm tubing between port #42 and port #43

The control unit did not cycle u Component problem inside the control unit u Call PIAB, 1-800-321-7422 to arrange



NOTE! The connections must be plugged when not in use.


Nylon tube dimension OD/ID




Filter shock 4/2 Brown 3 Filter shock signal

Pipe empty 4/2 Transparént 4 Pipe emptying signal


Fluid 4/2 White 6 Fluidisation signal

Pump 4/2 Green 7 Vacuum pump start signal

Level control 4/2 Grey 8 Level detector

VACUUM CONVEYORS

35

DIMENSIONCONTROL UNIT CU-1A, CU-1B, CU-2A, CU-2B WITH MOUNTING BRACKET ART. NO. 01 03 918

ART. NO. 01 03 919ART. NO. 01 03 920ART. NO. 01 03 921

VACUUM CONVEYORS

36

FUNCTIONS OF THE CONTROL UNITCONTROL UNIT CU-1A/B, CU-2A/B ART. NO. 01 04 550, 01 04 552

ART. NO. 01 04 540, 01 04 548

A Adjustable time for conveyingB Adjustable time for pipe line emptyingC Adjustable time for emptying of conveyor D 1 = Start of conveyor

0 = Stop of conveyor

CU-1A Art. No. 01 04 550CU-1B Art. No. 01 04 552

CU-2A Art. No. 01 04 540CU-2B Art. No. 01 04 548

VACUUM CONVEYORS

37

THE FOLLOWING FUNCTIONS CAN BE ADJUSTED BY THE OPERATOR

Control unit CU-1A

A Conveying time. Adjustable, 0.1–30 seconds.

C Time for emptying of conveyor. Adjustable, 0.1–30 seconds.

The bottom valve is open when the conveyor is turned off.

Control unit CU-1B



The bottom valve is closed when the conveyor is turned off.

Control unit CU-2A



B Time for pipe line emptying for each conveying cycle.

Adjustable 0.1–30 seconds.

The bottom valve is open when the conveyor is turned off.

Control unit CU-2B



B Time for pipe line emptying for each conveying cycle.

Adjustable, 0.1–30 seconds.

The bottom valve is closed when the conveyor is turned off.

VACUUM CONVEYORS

38

CONTROL UNIT CU-1B, BOTTOM VALVE NC ART. NO. 01 04 552

VACUUM CONVEYORS

39

PNEUMATIC DIAGRAMCONTROL UNIT CU-1A, BOTTOM VALVE NO ART. NO. 01 04 550

(

VACUUM CONVEYORS

40


VACUUM CONVEYORS

41


VACUUM CONVEYORS

42

TROUBLESHOOTING GUIDE: CONTROL UNIT PPT/R, PART # 01.06.066


No air to the control unit u Air is shut off·


u ·Connect the air supply to the pump

(40-100 psi)·

u Connect the 6mm tubing to the mani-

fold of the pump and the 6mm connec-

tion on the control unit·

u Turn the compressor ON·

u Locate the ball valve for the incoming

air supply·


The conveyor did not cycle

The conveyor does not completely shut

off

u ·The color-coded tubing are not connected

correctly·


pletely into connectors·

u The timers are set incorrectly

u ·Timer shuts off immediately·

u The O-ring may be misplaced or cracked in

the compressed air inlet of the pump (Not

valid with Classic L100)·

u One of the O-rings on the PPT/R timer

could be missing or cracked·

u Inadequate air pressure for shifting the shut-

tle valve on the pump (Not valid with Clas-

sic L100)

u ·Follow the color for each function of

the control unit·

u Connect corresponding color tubing

with matching control function port·


control connectors·

u Set the timers (V1=5sec, V2=2sec)V1

= 01.04.477 / V2 = 01.04.476

Timers do not contain stops / They will

continue turning, changing from maxi-

mum setting to minimum setting·

u Replace timer ·

u Replace O-ring on compressed air inlet

of the pump·

u Replace the O-ring on the PPT/R in the

area of air leak·

u Check air supply pressure

The control unit did not cycle u ·Material obstructing bottom door·

u To high (40 to 100 psi) a pressure coming

from the regulator on the PPT/R

u ·Clear any material that is obstructing

bottom door·

u Adjust the regulator on the PPT/R

clockwise until a pressure gauge

inserted into the PPT/R regulator reads

30 to 35 psi

Pump and PPT/R are cycling on and off,

but the bottom door will not open all the

way or at all

u ·The conveyor may be packed with material

/ preventing the release of vacuum in the

conveyor·

u To low (0 to 25 psi) a pressure coming from

the regulator on the PPT/R·

u Bottom door may be sticking to the bottom

seal

u ·Open conveyor and clean out all of the

productReset the PPT/R timers to 5

seconds on and 10 seconds off (Adjust

on and off timers to reduce waiting

time between cycles)·

u Adjust the regulator on the PPT/R

counter clockwise until a pressure

gauge inserted into the PPT/R regulator

reads 30 to 35 psi·

u Clean bottom seal, removing any mate-

rial stuck to it and any residue left

behind by the material

VACUUM CONVEYORS

43

FUNCTIONS OF THE CONTROL UNIT

A Adjustable time for conveyingB Adjustable time for emptying of conveyorC Regulator for opening of valve

VACUUM CONVEYORS

44

PNEUMATIC DIAGRAM(

COMPONENT LAYOUT

VACUUM CONVEYORS

45

TIME SIGNAL DIAGRAM

MOUNTING

VACUUM CONVEYORS

46

Connections for inlets and outlets(

General recommendationsFeed pressure: 0.4–0.6 MPa (58–87 psi)

Quality: The equipment requires dry and filtered(filtration grade 5 micron) compressed airaccording to ISO standard 8573.1, qualityclass 3.

We recommend that PIAB’s regulator kitshould always be used in order to ensureproper function. Use the 1/2" regulator kitfor 100–400 pumps (Art. No. 01 04 490)or regulator kit 1" for 600–1600 pumps(Art. No. 01 04 491).


Nylon tube dimensionOD/ID



Pump 4/2 Green 2 Starts vacuum pump

Shock 4/2 Brown 3 Filter shock



VACUUM CONVEYORS

47

DISASSEMBLING A PPT/R CONTROL

Please go through the other trouble shooting methods before disassembling the timers. Under clean, normal con-

ditions the PPT /R does not require routine maintenance. However in a dusty, dirty environment, the timers will need

to be re-lubricated. Please do not wash or spray the timers with water. The timers may be sent back and PIAB can

re-lubricate them, or the following instructions can be followed.

Helpful hints:

1. Make note of how each individual timer is installed. It is possible to install the timers upside down (rotated

180°), especially in the CU control. Please refer to drawing on page 37.

2. Only remove one timer from the controller at a time for service. The CU controller has two different types of

timers that cannot be mixed.

3. Only a small amount of lubrication is necessary, too much lubrication can damage the controller.

Procedure:

1. The A10 and C10 timers are composed of two parts. Separate the top of the timer from the base of the timer

by completely unscrewing and backing out the two screws found under the head assembly. Once the parts

have been separated, be careful not to loose any parts that may be loose. Make sure there are 3 o-rings on

the bottom of the timer. If one is missing or cracked this could be the problem.

2. The top of the timer is the portion that includes the adjustment knob. Set this portion aside.

3. The base of the timer is the portion that includes the mounting screws. This will need to be disassembled

further.

4. On the top of the base there is a brass assembly that is pressed into the black plastic base. Using a small

screwdriver or knife, pry this brass assembly out. There is an o-ring around the circumference of the brass

plate where it is in contact with the base, be very careful not to damage this o-ring.

5. The brass pieces can then be lifted from the base and separated.

6. If the brass pin will not slide easily, smear a small amount of lubricating grease around the brass pin. Try not

to use an excessive amount, as it can build up and clog the small orifices in the timer assembly. Do not put

any grease on the top of the pin that can cover the hole. If the pin slides easily, it does not need to be lubri-

cated.

7. Reassemble the brass assembly and put the assembly back into the base.

8. Push the brass pin down into the base assembly several times to confirm that it is moving smoothly and is

not sticking. It should pop up rather quickly and immediately.

9. Reassemble the top and base pieces of the timer and reinstall onto the base of the PPT/R Timer or CU Timer.

These PPT/R Timers are wear parts. There is a bellows suction cup inside of the timer that will wear after time. If

the timer has been re-lubed, all of the o-rings are in good condition, and it still will not work - a new timer will need

to be purchased.

VACUUM CONVEYORS

48

TROUBLESHOOTING GUIDE: CONTROL UNIT VCC-EP, PART # 34.07.016

Problem Possible Causes Possible SolutionsNo air to the control unit u ·Air is shut off·


u ·Connect the air supply to the pump

(40-100 psi)·



tion on the control unit·

u Turn the compressor ON·

u Locate the ball valve for the incoming

air supply·


The conveyor did not cycle

The conveyor does not completely shut

off

u ·The color-coded tubing are not connected

correctly·


pletely into connectors·

u Inadequate air pressure to the controller (air

supply port)·

u No air signal coming out of port #1 on the

VCC-EP when valve is manually depressed

or fired electronically ·

u The O-ring may be misplaced or cracked in

the compressed air inlet of the pump (Not

valid with L100)·

u Inadequate air pressure for shifting the shut-

tle valve on the pump (Not valid with L100

u ·Follow the color for each function of

the control unit·

u Connect corresponding color tubing

with matching control function port·


control connectors·

u Turn air supply to pump off / Discon-

nect the air supply tubing from the

VCC-EP control. Plug air supply tub-

ing into a pressure gauge, turn air sup-

ply on to the pump and verify air

supply pressure going to the VCC-EP

(40 to 100 psi)·

u Verify air supply to pump and VCC-EP

control unit

u ·Replace O-ring on compressed air

inlet of the pump·

u Check air supply pressure going into

air supply port of VCC-EP (40 to 100

psi)

Conveyor pump runs continuously and

will not shut off

u ·Material obstructing bottom door·

u Missing or damaged bottom seal

u ·Clear any material that is obstructing

bottom door·

u Check for the presence of a bottom seal

(clean seal if present)·

u Replace bottom seal

Pump and VCC-EP are cycling on and

off, but the bottom door will not open all

the way or at all

u ·The conveyor may be packed with material

/ preventing the release of vacuum in the

conveyor·

u Bottom door may be sticking to the bottom

seal·

u Signals to and from valves 4 and 5 on VCC-

EP control

u ·Open conveyor and clean out all of the

product·

u Clean bottom seal, removing any mate-

rial stuck to it and any residue left

behind by the material·

u Make sure there is a simultaneous elec-

tronic input to valves 4 and 5 on the

VCC-EP control or the bottom door

will not open

VACUUM CONVEYORS

49


Indications on the valve unit

(

General recommendationsFeed pressure: 0.4–0.6 MPa (58–87 psi)

Quality: The equipment requires dry and filtered(filtration grade 5 micron) compressed airaccording to ISO standard 8573.1, qualityclass 3.

We recommend that PIAB’s regulator kitshould always be used in order to ensureproper function. Use the 1/2" regulator kitfor 100–400 pumps (Art. No. 01 04 490)or regulator kit 1" for 600–1600 pumps(Art. No. 01 04 491).

Port name Port number Function

Air supply 0 Air supply inputOperating pressure 0.6 MPaPower supply 24V DC

Conveyor pump 1 Connected to start valve for vacuum pump

Fluidisation 2 Connected to 2/2 valve for start of fluidisation

Filter shock 3 Connected to 3/2 valve for filter shock

Discharge open 4 Connected to actuator to open bottom flap

Discharge close 5 Connected to actuator to close bottom flap

Electric inputs For electronic control signals to the connection block (2xØ6 mm)

Port label Nylon tube dimensionOD/ID

Tube colour Port Function

Air supply 6/4 Black 0 Air supply input.

Conveyor pump 4/2 Green 1 Connected to start valve for vacuum pump.

Fluidisation (Spare) 4/2 White 2 Connected to 2/2 valve for start of fluidisation.

Filter shock (Spare) 4/2 Brown 3 Connected to 3/2 valve for filter schock.

Discharge open 4/2 Blue 4 Connected to actuator to open bottom flap.

Discharge close 4/2 Yellow 5 Connected to actuator to close bottom flap.

Electric inputs 4/2 For electric control signalsto the connection block (2xØ6mm)

VACUUM CONVEYORS

50

VALVE CONNECTIONS FOR THE VCC-EP

VACUUM CONVEYORS

51

TROUBLESHOOTING GUIDE: LEVEL DETECTOR 24 VDC, PART # 01.00.267

TROUBLESHOOTING GUIDE: INJECTION UNITS, PART # 34.04.019 - 34.04.023

Problem Possible Causes Possible SolutionsConveyor will not turn on u Air is shut off·

u Product is covering the sensor on the Level

Detector(giving a false high level signal

u No 24 VDC going into the level detector

u Incorrect pressure coming out of port #8 on

CU controller

u Air signal tubing is not properly installed

into level detector or CU controller

u Level sensor is malfunctioning

u Connect the air supply to the pump

(40-100 psi)



tion on the control unit

u Open conveyor and remove any prod-

uct that is covering the level detector

u Connect power supply / If there is a

loss of power the CU controller will

shut down and need to be manually

reset

u Place an air pressure gauge into port #8

on the CU controller and verify air

pressure venting from port #8 is 30 - 40

psi

u Push tubing into each respective fitting

checking to make sure there is no air

leaking from each fitting

u Call PIAB, 1-800-321-7422 to arrange



Injection unit will not cycle u Air is shut off

u Pinch valve remains open

u Vacuum switch does not read any vacuum

u Pinch valve remains closed

u Pinch valve bladder is worn or ruptures

u Connect the air supply to the unit (87

psi)

u Connect the 6mm tubing to the air in

port on the switch control box

u Air supply to the injection unit is

greater than 87 psi, decrease air supply

u Verify that 4mm tubing is connected

between the vacuum port on the pump

(see diagram) and the vacuum port on

the switch control box

u Adjust vacuum switch to lower vac-

uum level by opening switch control

box and turn knob on top of vacuum

switch until pinch valve opens

u Call PIAB, 1-800-321-7422 to arrange


VACUUM CONVEYORS

52

LEVEL DETECTOR

� Function:The PIAB level detector is used together with the PIAB control unit, CU, to stop the conveyor when the detector is activated.

Technical data for capacitive gauge

Model Art. No. Feed pressureMPa (psi)

Voltage VDC Housingmaterial

Degree of protection

Weightg (lb)

Operating temperature°C (°F)

Level detector 01 00 267 0.2–0.6 (29–87) 24 PC, POM IP 54 622 (21.9) 0–50 (32–122)

Switching hysteresis Operatingtemperature °C (°F)

Degree ofprotection

Cable VoltageVDC

Output current max, mA

Max switching power W

10% of sensing distance –30 –70 (–22–158) IP67 PVC 3x0,5 mm2 10–35 300 7.2

Art. No. 01 00 267

VACUUM CONVEYORS

53

PNEUMATIC INJECTION VALVE

VACUUM CONVEYORS

54

CLEANING OUT A PACKED CONVEYOR

There are many reasons why a conveyor can get overly full of material. Most of the reasons have beennoted above. The important factor is how to clean the conveyor out. The easiest way to take apart theconveyor is to remove clamps and remove the pump and filter assembly. If there is not enough headroom,start from the bottom and remove module by module.

After removing the material from the main body of the conveyor, check to see if the material got pastthe filter. If it did, all of the parts above the filter should be cleaned out until there are no signs of thematerial. This includes any tubing and the air shock. Make sure the valve on the air shock is cleaned offand moves in and out easily. Please refer to diagram below. If the valve tends to stick, lubricate it. If thematerial is all the way up into the pump, please see page 23 for directions on how to clean out the pump.

VACUUM CONVEYORS

55

MAINTENANCE SCHEDULE

Explanation of the schedule

1. Check the feed pressure:The work pressure of the compressed-air supply ischecked during operation of the conveyor/pump.The operational pressure should be approximately0.5–0.6 MPa (72–87 psi).

2. Check the sealing:Check the conveyor by disconnecting the convey-ing hose/pipeline and applying a sealing rubbersheet against the end of the sleeve coupling whilethe pump is in operation. Read the vacuum levelon the vacuum gauge of the pump and comparethe value with the data sheet for the pump that isused. Repeat this checking procedure, but withthe feeding end of the conveying pipeline systemsealed.

3. Checking the pressure drop during conveying ofpowder:Read the vacuum gauge of the pump during nor-mal operation/conveying. Compare the vacuumlevel with the values obtained when checkingstart-up of the conveying system.

4. Checking the pressure drop during idling opera-tion:Read the vacuum gauge of the pump during idlingoperation without conveying any powder. Carry outthe first check at start-up (date of start) and doc-ument the value in the table to the right above.When the pressure drop during idling has risen(and the vacuum level has decreased) by approxi-mately 5–10 -kPa (1.5–3"Hg)as compared to thestart value, this is an indication that the filterneeds to be washed/changed.

5. Washing the filter:A contaminated Pitex filter bag can be washed in-stead of being changed. The filter can normally bewashed 2–4 times. The filter bag can be washedin a normal washing machine in 40°C (104°F)“cold wash” or corresponding hand wash.

Gore Sinbran filters should be cleaned carefullywith a soft brush under running water at low pres-sure in order not to destroy the membrane of thefilter. Gore Sinbran filters may not be washed butthey can be sterilised for 30 minutes at 120°C(248°F).

Time interval Check/messure Daily Each

monthEvery second

monthEvery sixth

monthAccording to experience

Date of start of new installation

..................................

Pressure drop at idling at date of start

............. -kPa (-in Hg)

Date of filter change or filter washing

1 Check of feed pressure X

2 Check of sealing,conveyor/system

X

3 Check of pressure drop during conveying

X

4 Check of pressure drop during idling

X

5 Washing of filter X (X)

6 Change of filter/Check of air shock function

X (X)

7 Emptying of filter regulator/change of filter kit

X

8 Dismounting,cleaning/washing and checking

X X (X)

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56

6. Change of filter:NOTE: Only for Pitex filtersA change of filter shall be made at least once eve-ry six months or after having washed the filter 2–4 times. Notice that changing/washing of filtermay, due to hygienic reasons in food applications,be required at shorter intervals.

7. Emptying of filter regulator/change of filter kit:Check and dispose of possible contamination andwater in the filter regulator on the feed pipelineonce every two months. The filter kit of the filterregulator should be replaced once every year.

8. Dismantling, cleaning and checking: The conveyor should be dismantled regularly forchecking and cleaning. For sanitary reasons, inthe the chemical and food industry, daily disman-tling and washing are sometimes required.

CLEANING THE CONVEYOR

The whole conveyor should be disassembled at reg-ular intervals for checking and cleaning. Due to hygi-enic reasons in the food and pharmaceutical indus-tries there may be requirements for daily washingaccording to applicable regulations.

NOTE: The conveyor is not designed for CIP – CleanIn Place.

The supply of compressed air shall be disconnectedfrom the pump. Dismount the pump and the upperpart of the filter unit and the air shock tanks. Allthese parts are on the “clean side” of the filter, i.e.,they do not come in contact with the conveyed pow-der. Loosen the remaining clamp rings and dismountthe modules, seals (see below) and the filters (seebelow). The steel parts can be washed with waterand detergent according to local regulations. It is im-portant to clean all parts that come in contact withthe conveyed powder.

SealingsThe material in the silicone sealings has been testedand approved according to the 3-A Sanitary Stand-ards No. 18-03, Class II. This means, among otherthings, that it has been tested in alkaline cleanertest solution for 22 hours at 82°C (179.6°F) and ni-tric acid (0.5%) for 22 hours at 82°C (179.6°F).

The material in the nitrile sealings has been testedand approved according to the 3-A Sanitary Stand-ards No. 18-03, Class III. This means, among otherthings, that it has been tested in alkaline cleanertest solution for 22 hours at 82°C (179.6°F) and or-tophosphoric acid (1.0%) for 22 hours at 82°C(179.6°F).

The silicone- and nitrile rubber materials are in com-pliance with FDA CFR 21 § 177.2600 ”Rubber arti-cles intended for repeated use”.

WARRANTY

PIAB gives a 5-year warranty for its conveyors andvacuum pumps. For accessories the guarantee is 1year. The warranty does not apply to filters and otherconsumable par

VACUUM CONVEYORS

57

NOTES

VACUUM CONVEYORS

58

NOTES

VACUUM CONVEYORS

59

NOTES

ASIA PACIF IC (S INGAPORE)Asia Pacific Pte Ltd

27 Mandai Estate #05-02Innovation Place Tower 2SINGAPORE 729935Tel 65-6368 2348Fax 65-6368 [email protected]

AUSTRALIAVacuum Technologies Pty. Ltd.

17 Southfork DriveKILSYTH, VIC 3137Tel 61-3 9728 8653Fax 61-3 9728 [email protected]

BRAZILDo Brasil Ltda.

Av. Indianopolis, 1725 - Planalto PaulistaBR-04063-003 SAO PAULO-SPTel 55-11 5589 8955Fax 55-11 5589 [email protected]

FRANCES.A.

Parc d’Entreprises EsplanadeSaint Thibault-des-VignesFR-77462 LAGNY SUR MARNE CEDEXTel 33-1 64 30 82 67Fax 33-1 64 02 87 [email protected]

GERMANYVakuum GmbH

Pfingstweide 41D-61169 FRIEDBERGTel 49-6031 71840Fax 49-6031 [email protected]

GREAT BRITAINLtd.

P.O. Box 43GB-LOUGHBOROUGH Leicestershire LE12 8NYTel 44-1509 814 280Fax 44-1509 814 [email protected]

ITALYITALIA Srl

Via Schiaparelli, 10IT-10148 TORINOTel 39-011 226 36 66Fax 39-011 226 21 [email protected]

PIAB G IVES YOU SERVICE ALL OVER THE WORLD

JAPANJapan Ltd.

3-11-23 Hikawacho, Todo-shi,Saitama-ken 335-0027Tel 81-48 443 9148Fax 81-48 443 [email protected]

L AT IN AMERICA (COLOMBIA )Latin America

Carrera 16 No. 86A-76SANTA FE DE BOGOTÁ, ColombiaTel 57-1 636 1953Fax 57-1 636 [email protected]

SOUTH AFRICA(Pty) Ltd.

P.O. Box 23512CLAREMONT, Cape Town 7735Tel 27-21 447 5110Fax 27-21 448 [email protected]

SPAINVacío S.L.Ctra. Llobatona, s/n, nave 12ES-08840 VILADECANS BARCELONATel 34-93 638 90 91Fax 34-93 638 08 [email protected]

SWEDENAB

Box 4501SE-183 04 TÄBYTel 46-8 630 25 00Fax 46-8 630 26 [email protected]

SWITZERL ANDVakuum AG

Industrie Neuhof 9Postfach 400CH-3422 KIRCHBERGTel 41-34 448 24 24Fax 41-34 448 24 [email protected]

USAUSA, Inc.

65 Sharp StreetHINGHAM, MA 02043Tel 1-781 337 7309

1-800-321-PIABFax 1-781 337 [email protected]

www.piab.com

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c series conveyor troubleshooting guide

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